Apparatus for manufacturing a molded product, and molded product that can be manufactured with the apparatus

ABSTRACT

The present invention provides a rotary press that allows mass production of a molded product. The rotary press has upper and lower punches that may be split in to a plurality of split punches, a means for moving the split punches, and a means for manipulating the plurality of split punches. In addition, the rotary press also has a plurality of molding material supply-charging units for supplying and charging molding materials into the space formed by the tip portions of the split punches, a precompression molding unit and a main compression molding unit for compression-molding the molding materials supplied and charged the entire molded product, respectively. Optionally, a unit to remove residual molding material remaining on the lower punches and/or the temporary molded product may be provided.

The application disclosed herein corresponds to InternationalApplication No. PCT/JP02/08695, filed Aug. 28, 2002, which claimspriority of Japanese Serial No. 2001-260924, filed Aug. 30, 2001, andJapanese Serial No. 2001-325284, filed Oct. 23, 2001, the contents ofwhich are incorporated into this application.

TECHNICAL FIELD

The present invention relates to an apparatus for manufacturing a moldedproduct by pressing molding materials, a method for manufacturing amolded product with the apparatus and a molded product that can bemanufactured by the manufacturing method. More particularly, theinvention relates to a rotary press for manufacturing a molded productconsisting of a plurality of molded parts part of whose at least twomolded parts faces outside of the molded product, a method formanufacturing a molded product with the press and a molded product andso on whose characters and/or graphics can be externally identified.

BACKGROUND ART

Drugs, foods, sanitary products, living miscellaneous goods, sinteredstructural parts, electronic parts and semiconductors are among areas inwhich molded products are manufactured by pressing a variety ofmaterials. While molded or semi-molded products in all these areas aremanufactured by pressing molding materials into an intended shape, presssystems are actually commonly different depending on characteristics ofintended molded products and requested needs.

Molded products used for drugs, foods, sanitary products and livingmiscellaneous goods are relatively simple in shape, can be pressed atlow pressures and further generally use rotary presses that canmanufacture molded products at high speed out of needs for manufacturingan exceedingly large number of products at low cost. Rotary press, inwhich a plurality of dies are arranged on a turn table, with punchesheld thereabove and therebelow and in which the turn table is moved inthe direction of rotation, manufactures molded products by continuoussupply of molding materials, pressing and ejecting of molded products.Normally capable of manufacturing several thousands of molded productsper minute, rotary presses mainly feature a remarkably high productivityas compared with stroke presses that will be discussed later.

On the other hand, stroke presses are chiefly employed for moldedproducts in areas such as sintered structural parts, electronic partsand semiconductors that are more complicated in shape and requirepressing at high pressures. As for stroke presses used in metal workingareas including sintered structural parts, for example, pressurizedcylinder type and eccentric cam type presses are generally used. Thesepresses are designed to press-mold molding materials by moving punchesheld above and below a die in relative directions. Such presses arecommonly characterized in using a single die to supply moldingmaterials, press and eject molded products and allow, because of theirsimple structure, manufacture of molded products requiring pressing athigh pressures, molded products in complicated shape using multipunchand molded products of extremely high precision. However, such pressesare low in production efficiency due to the structure and press systemthereof and therefore not suited for mass production—disadvantages ascompared with rotary presses.

In stroke presses, pairing of a die and punches can be generally broadlydivided into stationary die-movable lower punch system and stationarylower punch-movable die system—a system generally called withdrawaldieset. Similarly in press system, some use hydraulic or pneumaticcylinders to apply pressure while others employ a system such as CNC(Computer Numerical Control) equipped with an electronic controller,servo-driven ball screw, etc.

Also in rotary presses, methods for producing shapes of a certain degreeof complexity have been disclosed in the case of a single moldingmaterial rather than a plurality of molding materials. Ring-shapedpunches, as in the lower punch mechanism of the rotary powdercompression molding machine recited in Japanese Unexamined PatentApplication Publication No. 52-126577, are designed to ensure uniformbulk material density during molding by moving the lower center andouter punches separately and charging bulk material in accordance withthe shape of the final molded product. However, since suchmultistructured punches—conventional so-called ring-shaped punches—areused to aid in charging of bulk material, no consideration has beengiven to manufacturing a molded product consisting of a plurality ofmolded parts.

Rotary press for press-coated tablets used in the area of drugs is amongapparatuses for manufacturing molded products consisting of a pluralityof molded parts. The manufacturing method for press-coated tablets usinga rotary press for press-coated tablets is by manufacturing in advancecore with a separate rotary press, feeding the coatings into the die ofa rotary press for press-coated tablets supplied with an outer-layerbulk material and further feeding and press-molding the outer-layer bulkmaterial. According to the method, it is possible to arrange differentconstituents at the center and on the outside. In the method for feedingcoatings into the die, however, it is substantially impossible to feed acoating identical to the die inner diameter or accurately localize aplurality of coatings at specific positions because present rotarypresses for press-coated tablets have difficulties accuratelypositioning a coating at the center of the die, and therefore it isextremely difficult to divert a rotary press for press-coated tabletsfor manufacturing non-coated molded products consisting of a pluralityof molded parts.

On the other hand, in sintered structural parts or the so-calledmetallurgy area, a method for manufacturing a molded product containinga plurality of constituents in a localized manner has been disclosed inJapanese Unexamined Patent Application Publication No. 52-2817. ThePublication recites a method (FIG. 2) for manufacturing a molded productin which different bulk materials are localized perpendicularly to thepressure application surface, as shown in FIGS. 1(A), 1(B) and 1(C) (itshould be borne in mind that while the molded product in the Publicationis in troche form with a hollow at the center and with a center pinprovided for securing the hollow, the substantial form is the same asthose shown in FIGS. 1 and 2). According to the method, multipunches areused for both the upper and lower punches, and one of the lower punchesis lowered relative to the die first, and a powdered material is fedinto a created space. Then, the upper punch corresponding to the lowerpunch is lowered to mold under pressure the powdered material betweenthe lower punch, the die and the upper punch. Then, a lower punchdifferent from the lower punch is lowered relative to the die, with thealready molded powdered molded compact left in the mold hole. A powderedmaterial different from the powdered material is supplied and thenmolded under pressure together with the temporary molded product tomanufacture a molded product. Although the manufacturing method isassumably intended for a stroke press judging from the area, the methodpresents a number of manufacturing problems.

Thus, no prior art substantially exists since there is no method formanufacturing a non-press-coated molded product consisting of aplurality of molded parts as industry at present.

In medical workplaces, for example, where white round tablets arepredominant, on the other hand, tablet identifiability is an importantissue. The reason is that information such as product names, contents ofprincipal agents and manufacturers must be discernible when tablets arein random orientations after being taken out of their packages, and suchinformation is used for confirmation and other purposes in medicinepreparation and when patients take medicines. Today, “tablet codes”(codes by combination of characters and graphics) has been introduced asa tablet identification method, and the Federation of PharmaceuticalManufacturers' Associations of JAPAN (FPMAJ) has defined “theIdentification Code Implementation Procedure for Tablets and Capsules”in the FPMAJ Issue 80 that is now practiced by pharmaceuticalsmanufacturers as a voluntary arrangement.

Tablet codes can be printed by printing characters and other informationon the tablet surface by ink or engraved by pressing a punch of convexshape on the surface thereof against a molded product, compacting thetablet and thereby producing a concave engraved code on the tabletsurface. Among these, the printing method has had a variety of problemsincluding complication of steps, cost aspect, use of organic solventsand rigorous technical requirements in printing step such as “printdeviation.”

On the other hand, the engraving method accounts for 70 to 80% oftablets on the whole. However, this method has problems such asdifficulties in seeing codes, resulting in a hindrance toidentifiability of tablet codes. As compared with tablet printing,nevertheless, engraving does not require tablet coating—a step necessaryin printing. Additionally, engraving is simpler with less manufacturingsteps, thus allowing manufacturing cost reduction. Further, engravingrequires no use of organic solvents needed in printing, resulting inwidespread use because of its freedom from printing problems such as“print deviation.”

While there may be a variety of reasons for difficult-to-see engraving,such a difficulty is commonly thought to be attributed to its form.Since engraving is intended, by producing a concave indentation on amonochrome tablet, to render the code legible with the shadow created bythe indentation and the tablet surface, it is known that the code isless legible due to halation at a relatively bright location such asunder a fluorescent lamp, making engraving obviously inferior in termsof identifiability to printing in which characters are clearlydiscernible by color difference.

Many areas other than drugs produce molded products by compressingmolding materials as well. In such molded products, characters andgraphics are often added for the purpose of enhancing product addedvalues, from design aspect, for trademark addition and so on. However,such molded products are commonly manufactured by the same manufacturingmethod as with the aforementioned tablets in drugs, thus entailing thesame problems.

DISCLOSURE OF THE INVENTION

As described above, in manufacturing a non-press-coated molded productconsisting of a plurality of molded parts, there have been nomanufacturing methods or apparatuses conventional art suited for massproduction. Therefore, the present invention has been perfected with anobject to provide a manufacturing method and apparatus that allows massproduction of a molded product consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct. The present invention also provides codes for impartingidentifiability to a molded product, for example, a molded product withenhanced identifiability through identification by color difference asin the printing method using the manufacturing method and the apparatusto solve a variety of problems associated with tablet codes. The presentinvention will be described below together with the progress until thepresent invention was arrived at.

First, the present inventor investigated whether a molded productconsisting of a plurality of molded parts using a plurality of moldingmaterials could be manufactured by reviewing various conventional pressmethods.

First, stroke presses equipped with multipunches suited for manufactureof complicated shapes were investigated due to the fact that the methodrecited in Japanese Unexamined Patent Application Publication No.52-2817 assumes a stroke press, and increasing the number of punches anda die hole was examined. More punches and a die hole considerablyincrease production volume per step, thus enhancing productivity to alevel close to rotary presses. Such an increase in punches and a diehole seemingly allows relatively easy manufacture of products ofcomplicated shape in large volumes using a single molding material.However, this option requires a large compression pressure needed forpressing a large quantity of products in a single step, resulting in newproblems such as scaleup of the press itself and lower speed in pressoperations.

When a molded product consisting of a plurality of molding materials ismanufactured, accurately charging a plurality of molding materials in asingle step is naturally difficult because of charging quantityadjustment and contamination with other molding materials, requiringmolding materials to be individually charged. That is, to clarify aboundary between parts into which a plurality of molding materials arecharged and a device for adjusting charging quantities, there are timeswhen post-charging compression of individual molding materials bypunches is necessary. However, stroke presses generally convertrotational energy from the motor to vertical motion using eccentric cam,etc., and the distance between the tips of the upper and lower punchesin the die is, because of this structure, determined by cam shape and/orcam position. The punch-to-punch distance is relevant to charging ofmolding materials into the die associated with lowering of the lowerpunch, pressing of the molded product and unloading thereof. If thepunch-to-punch distance is constant and if a molded product ismanufactured using a plurality of molding materials, the punch-to-punchdistance becomes the same between when a first molding material ischarged and pressed and when a second molding material is charged andpressed, with the molded product molded earlier held on top of the lowerpunch, making it impossible to control the second charging quantity andthe pressure for second pressing. As a countermeasure, it is necessaryto manually reduce the charging quantity of the first molding materialor change the cam shape or position during the second pressing everytime. If continuous production is intended, however, thesecountermeasures are deemed industrially unpractical.

When the compression method is switched from eccentric cam to hydrauliccylinder or servomotor using ball screw, while the punch-to-punchdistance can be adjusted in the second charging and pressing, adjustmentby hydraulic cylinder does not allow fine tuning, and long hours ofcontinuous operation are impossible due to occurrence of bubbles in thehydraulic cylinder. In contrast, servomotor-driven compression can clearthe problems presented by hydraulic cylinder, but is deemed unfit forhigh-speed continuous pressing because of its slow operation.

Another problem involved in manufacturing a molded product consisting ofa plurality of molding materials with a stroke press is difficulties infinely adjusting charging quantities of individual molding materialsevery pressing due to the structure. The term “every pressing” refers tocharging quantity adjustment every pressing during a cycle of moldedproduct manufacture rather than initial setting of charging quantity ofeach of a plurality of molding materials.

Physical shapes of molding materials used for metallurgy, molding ofepoxy resin products and so on—areas in which stroke presses arecommonly employed—are often uniform in particle distribution andconstant in density. Therefore, molded products produced in an earlystage of pressing do not differ much in weight from those produced in alater stage even if initial setting of charging quantity is in a statefixed without fine adjustment every pressing. However, molding materialsused for drugs and foods are mixtures of a variety of materials andnormally vary in particle distribution, density and so on. Variation incharging caused by these variations translates into variation in productweight and further leads to molding failure attributed to insufficientcharging. As a method to eliminate these variations, therefore, rotarypresses, noting the fact that the stress occurring during compressionmolding is proportional to the amount of raw material, have adopted amechanism that compares the signal with the control standard value setin advance and sends a feedback, in the event of discrepancy, to apowder charging unit to perform weight adjustment (Powder CompressionMolding Technology edited by Medicine Manufacturing and Particle DesignGroup of The Society of Powder Technology, Japan Nikkan Kogyo ShimbunP.111). Weight adjustment of each of a plurality of molding materials ismade possible by the fact that rotary press has as many physicallyindependent charging units as the number of a plurality of moldingmaterials on its turn table and is constructed such that chargingdevices of the independent charging units can move independently fromother charging units. In other words, rotary press has a structure toallow instantaneous weight adjustment of individual molding materials.To equip a stroke press with such a feedback mechanism, however, whileonly one charging device is required for adjusting charging quantity ofeach of a plurality of molding materials, adjustment of chargingquantity for each part must be made for each of a plurality of moldingmaterials, thus resulting in a complex apparatus. Further, charging of amolding material for a next part cannot be adjusted due to the mechanismuntil charging of a molding material for a previous part is complete,making it impossible to instantaneously adjust weight of each of themolding materials and thereby preventing high-speed pressing. That is,charging quantities of molding materials into the die cannot be changedevery pressing, making it, in much probability, substantially impossibleto adjust charging quantity of each of a plurality of molding materials.

Another problem involved in manufacturing a molded product consisting ofa plurality of molding materials with a stroke press is the need toarrange a plurality of feed shoes (devices for storing and chargingmolding materials) for charging molding materials into the die. Asindicated earlier, it suffices, in the case of a rotary press, toarrange on the turn table as many feed shoes as the number of aplurality of molding materials according to the sequence of charging. Inthe case of a stroke press substantially consisting of a die andpunches, however, the number of feed shoes around the die increases withincreasing number of molding materials. Motions of individual feed shoesbecome complicated, with the feed shoe moving mechanism becomingcomplicated as well, making it industrially impossible to manufacture amolded product consisting of a plurality of molding materials with astroke press.

On the other hand, it has been discovered that an attempt tomass-produce a molded product, in which different bulk materials arelocalized perpendicularly to the pressure application surface, usingJapanese Unexamined Patent Application Publication No. 52-2817 recitedearlier in background art faces a significant problem. The problem liesin contamination taking place between different bulk materials duringmanufacture. In the method of the Japanese Unexamined Patent ApplicationPublication No. 52-2817 (FIG. 2), a temporary molded product consistingof either one of the bulk materials is molded first (FIG. 2D), and thenthe other bulk material is charged into a space surrounded by thetemporary molded product, the lower punch, the die, etc. (FIG. 2G) andcompression-molded (FIG. 2M). Depending on the position of the temporarymolded product molded earlier, however, the bulk material may be chargedinto unnecessary portions in the next step. More specifically, if theupper surface of the molded product is lower than the upper surface ofthe die as shown in Step C of FIG. 4, bulk material is supplied onto theupper surface of the temporary molded product molded earlier during bulkmaterial supply shown in Step D. Such bulk material is impossible toremove by rubbing and cutting and prevents manufacture of a compositemolded product as shown in FIG. 1 if compressed as is. Conversely, ifthe upper surface of the molded product is higher than the upper surfaceof the die as shown in Step C of FIG. 3, the temporary molded product isdamaged by a rubbing-cutting plate in the Step E—step for rubbing andcutting following bulk material supply in Step D. These problems do notoccur if the post-pressing height of the temporary molded product isconstantly in agreement with that of the die upper surface (FIG. 2F) aswith the method recited in the Publication. However, when each oftemporary molded products is actually manufactured, it seemsindustrially impossible to adjust the height of the molded product uppersurface relative to individual temporary molded products while at thesame time taking in consideration variation in charging of individualbulk materials, post-compression plasticity, elastic deformation, etc.of the molded product.

Further, we suppose that a multipunch is used as the lower punch asshown in Step A of FIG. 22(1) and that the lower punch is arranged suchthat the extreme tip surface (extreme tip portion) of the lower punchmatches with the die upper surface. If, in this case, a molded productconsisting of two or more types of molding materials is manufacturedusing a punch having a shape in which a concave surface exists on thelower punch side relative to the die upper surface, in other words, ashape that results in unnecessary bulk material being supplied to theconcave portion on the upper tip surface, removal of residual bulkmaterial on the lower punch by the conventional rubbing-cutting methodis impossible, and contamination between the bulk material of a nextstep and the residual bulk material is unavoidable.

As a result of trial and error as described above, the present inventorhas devised a rotary press for manufacturing a molded product consistingof a plurality of molded parts part of whose at least two molded partsfaces outside of the molded product, the rotary press having a rotatableturn table, provided with a die having a die hole and holding upper andlower punches above and below the die so as to be vertically slidable,and being designed to compress molding materials supplied and chargedinto the die by moving the upper and lower punches in mutuallyapproaching directions and pressing the molding materials with the punchtips in a state inserted in the die, the rotary press comprising atleast the upper punch split into a plurality of punches, means formoving the respective split punches and allowing manipulation of atleast two of the plurality of split punches for compression operation, afirst molding material supply-charging unit for supplying and charging afirst molding material into a space in the die formed above the tipportion of the lower punch or formed by the tip portions of splitpunches of the lower punch, a second molding material supply-chargingunit for supplying and charging a second molding material into a spaceformed above and/or around the first molding material in the die, aprecompression molding unit for compress ion-molding at least one of themolding materials supplied and charged and a main compression moldingunit for compression-molding the entire molded product. The rotary pressis normally constructed to have the lower punch split into a pluralityof punches as with the upper punch and comprises means for movingrespective punches of the plurality of punches and for allowingmanipulation of at least two of the plurality of split punches forcompression operation. The rotary press also comprises, as necessary,devices for removing residual molding material on the lower punch and/orthe temporary molded product.

To solve a variety of problems involved in engraving tablets such aspoor identifiability and overcome numerous problems associated withprinting, on the other hand, the present inventor has devised a new codeidentification system for molded products using the aforementionedrotary press. The molded product is characterized in that the productconsists of a plurality of molded parts part of whose at least twomolded parts faces outside of the molded product, in that charactersand/or graphics is shaped by at least one molded part, that the moldedpart shaping the characters and/or graphics differs from other moldedparts in color and that the characters and/or graphics can be externallyidentified. The molded product provides considerably improvedidentifiability to characters and/or graphics to be identified byrepresenting the characters and/or graphics to be identified with somemolded parts and by using different colors for the molded partsrepresenting the characters and/or graphics and the other molded parts.The molded product can be manufactured by using the rotary pressaccording to the present invention, employing a punch having a tipportion shaped to represent characters and/or graphics at least for theupper punch and using at least two molding materials that differ fromeach other in color.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1(A), 1(B) and 1(C) illustrate an embodiment (first example) of amolded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 1(A) being a side view, FIG. 1(B) being atop view, and FIG. 1(C) being a perspective view;

FIG. 2 illustrate explanatory views of punch tip operations showing anexample of conventional molded product manufacturing method in which aplurality of molding materials are localized (shading as cross sectionomitted);

FIG. 3 illustrate explanatory views of punch tip operations showing anexample of problem in the rubbing-cutting step in the conventionalmolded product manufacturing method shown in FIG. 2 in which a pluralityof molding materials are localized (shading as cross section omitted);

FIG. 4 illustrate explanatory views of punch tip operations showinganother example of problem in the rubbing-cutting step in theconventional molded product manufacturing method shown in FIG. 2 inwhich a plurality of molding materials are localized (shading as crosssection omitted);

FIG. 5 illustrate explanatory views of punch tip operations showing afirst example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 1) consisting of a plurality of molded parts partof whose at least two molded parts faces outside of the molded product(shading as cross section omitted);

FIGS. 6(A), 6(B) and 6(C) illustrate an embodiment (second example) of amolded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 6(A) being a side view, FIG. 6(B) being atop view, and FIG. 6(C) being a perspective view;

FIG. 7 illustrate explanatory views of punch tip operations showing asecond example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 6) consisting of a plurality of molded parts partof whose at least two molded parts faces outside of the molded product(shading as cross section omitted);

FIGS. 8(A), 8(B) and 8(C) illustrate an embodiment (third example) of amolded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 8(A) being a side view, FIG. 8(B) being atop view, and FIG. 8(C) being a perspective view;

FIG. 9 illustrate explanatory views of punch tip operations showing athird example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 8) consisting of a plurality of molded parts partof whose at least two molded parts faces outside of the molded product(shading as cross section omitted);

FIGS. 10(A), 10(B) and 10(C) illustrate an embodiment (fourth example)of a molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 10(A) being a side view, FIG. 10(B) being atop view, and FIG. 10(C) being a perspective view;

FIG. 11 illustrate explanatory views of punch tip operations showing afourth example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 10) consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct (shading as cross section omitted);

FIGS. 12(A), 12(B) and 12(C) illustrate an embodiment (fifth example) ofa molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 12(A) being a side view, FIG. 12(B) being atop view, and FIG. 12(C) being a perspective view;

FIG. 13 illustrate explanatory views of punch tip operations showing afifth example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 12) consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct (shading as cross section omitted);

FIGS. 14(A), 14(B) and 14(C) illustrate an embodiment (sixth example) ofa molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 14(A) being a side view, FIG. 14(B) being atop view, and FIG. 14(C) being a perspective view;

FIG. 15 illustrate explanatory views of punch tip operations showing asixth example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 14) consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct (shading as cross section omitted);

FIGS. 16(A), 16(B) and 16(C) illustrate an embodiment (seventh example)of a molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 16(A) being a side view, FIG. 16(B) being atop view, and FIG. 16(C) being a perspective view;

FIG. 17 illustrate explanatory views of punch tip operations showing aseventh example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 16) consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct (shading as cross section omitted);

FIGS. 18(A), 18(B) and 18(C) illustrate an embodiment (eighth example)of a molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 18(A) being a side view, FIG. 18(B) being atop view, and FIG. 18(C) being a perspective view;

FIG. 19 illustrate explanatory views of punch tip operations showing aneighth example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 18) consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct (shading as cross section omitted);

FIGS. 20(A), 20(B) and 20(C) illustrate an embodiment (ninth example) ofa molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 20(A) being a side view, FIG. 20(B) being atop view, and FIG. 20(C) being a perspective view;

FIG. 21 illustrate explanatory views of punch tip operations showing aninth example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 20) consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct (shading as cross section omitted);

FIG. 22(1) illustrate explanatory views of punch tip operations whennormal lower split punches are used, and FIG. 22(2) illustrateexplanatory views of punch tip operations when a lower split punchstructure is adopted for reducing residual molding material on the lowerpunches in the molding product manufacturing apparatus according to thepresent invention (shading as cross section omitted);

FIG. 23 illustrates an overall front sectional view of a common rotarypress, although with no sectional views of punches, vertical shaft andhopper shown;

FIG. 24 illustrate top views of example shapes of punch tip portionshaving a split punch structure used in the present invention, with theshapes classified into four series A to D according to the split form;

FIGS. 25A to 25E2 illustrate the diversity of molded products that canbe manufactured using a punch having the single split punch structure inthe present invention, with A showing the shape of a punch tip portionconsists of a double structure, and series B to E showing aclassification of molded products that can be manufactured from thepunch focusing attention on concave and convex structures of moldedparts provided at the center;

FIG. 26 illustrate specific examples in which split punch structureswith different split shapes are used for upper and lower punches in thepunches having the split punch structure used in the present invention,with FIGS. 26A-1 and 26B-1 showing upper punches, FIGS. 26A-2 and 26B-2showing lower punches, and FIGS. 26A-3 and 26B-3 showing sectional viewsof punch tips when tips of upper and lower punches are brought close toeach other as in actual use (shading showing cross section omitted);

FIGS. 27(A), 27(B) and 27(C) illustrate an example of punch having thesplit punch structure used in the present invention, with FIG. 27(A)being a vertical sectional view (right half) and schematic diagram (lefthalf), FIG. 27(B) being a side view, and FIG. 27(C) being a top view ofthe punch tip portion;

FIG. 28 illustrates an example of punch having the split punch structureused in the present invention, showing a vertical sectional view (righthalf) and schematic diagram (left half);

FIGS. 29(A), 29(B), 29(C), and 29(D) illustrate an example of punchhaving the split punch structure used in the present invention, withFIG. 29(A) being a schematic diagram, FIG. 29(B) being a sectional view,FIG. 29(C) being a side view, and FIG. 29(D) being a top view of thepunch tip portion;

FIGS. 30(A), 30(B) and 30(C) illustrate an example of punch having thesplit punch structure used in the present invention, with FIG. 30(A)being a vertical sectional view (right half) and schematic diagram (lefthalf), FIG. 30(B) being a side view, and FIG. 30(C) being a top view ofthe punch tip portion;

FIG. 31 illustrates a schematic plan view showing a turn table in anembodiment of the rotary press of the present invention;

FIG. 32 illustrates a schematic diagram including some sectional portionshowing the operation mechanism of the upper and lower punches bydeveloping the turn table in an embodiment of the rotary press of thepresent invention;

FIGS. 33(A) and 33(B) illustrate a residual molding material removaldevice of the present invention, with FIG. 33(A) being a bird's-eyeview, and FIG. 33(B) being a top view;

FIGS. 34(A), 34(B) and 34(C) illustrate an embodiment (tenth example) ofa molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 34(A) being a side view, FIG. 34(B) being atop view, and FIG. 34(C) being a perspective view;

FIG. 35 illustrate explanatory views of punch tip operations showing atenth example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIG. 34) consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct (shading as cross section omitted);

FIGS. 36(A), 36(B) and 36(C) illustrate an embodiment (eleventh example)of a molded product manufactured by the manufacturing apparatus of thepresent invention, with FIG. 36(A) being a side view, FIG. 36(B) being atop view, and FIG. 36(C) being a perspective view;

FIG. 37 illustrate explanatory views of punch tip operations showing aneleventh example of manufacturing steps using the manufacturingapparatus of the present invention for a molded product (correspondingto the molded product in FIG. 36) consisting of a plurality of moldedparts part of whose at least two molded parts faces outside of themolded product (shading as cross section omitted);

FIGS. 38(A), 38(B) and 38(C) illustrate an example of molded product ofthe present invention whose characters and/or graphics can be externallyidentified, with FIG. 38(A) being a side view, FIG. 38(B) being a topview, and FIG. 38(C) being a perspective view;

FIGS. 39(A), 39(B) and 39(C) illustrate an example of molded product ofthe present invention whose characters and/or graphics can be externallyidentified, with FIG. 39(A) being a side view, FIG. 39(B) being a topview, and FIG. 39(C) being a perspective view;

FIG. 40 illustrate specific examples of punches having the split punchstructure used for manufacturing a molded product of the presentinvention whose characters and/or graphics can be externally identified,with shapes of split punches (e.g., center and outer punches) side byside;

FIG. 41 illustrate explanatory views of punch tip operations showing atwelfth example of manufacturing steps using the manufacturing apparatusof the present invention for a molded product (corresponding to themolded product in FIGS. 42B-1 and 42B-2) consisting of a plurality ofmolded parts part of whose at least two molded parts faces outside ofthe molded product (shading as cross section omitted); and

FIGS. 42A-1 to 42D2 illustrate a molded product manufactured in theembodiment shown in FIG. 41 and the diversity of molded products thatcan be manufactured by slightly modifying the punch operations, withFIGS. 42A-1 to 42D-1 being sectional views of molded products, and FIGS.42A-2 to 42D-2 being schematic diagrams of the molded products.

BEST MODE FOR CARRYING OUT THE INVENTION

In this description, the term “molding material” is defined as anymoldable material including bulk material while the term “bulk material”as powder, granules and something similar thereto. In the presentinvention, bulk material is preferably used as molding material.

A molded product intended by the present invention is that whichconsists of a plurality of molded parts part of whose at least twomolded parts faces outside of the molded product. In such a moldedproduct, two or more types of molding materials are substantiallylocalized respectively as molded parts, and part of at least two moldedparts thereamong faces outside of the molded product. That is, ordinarypress-coated products, in which one molded part is entirely covered byanother molded part, are excluded. It should be noted that molded partsmean individual partial molded bodies making up the whole of a moldedproduct in the present specification, with each molded part constitutedby a single molding material, and are produced by compressing moldingmaterials charged into molds (including a space surrounded by a dieand/or punches). It should also be noted that if, for instance, amolding material acquires a new added value as a result of differentphysical property (e.g., particle size, crystal shape) from the originalmaterial despite identical constituents in terms of chemical substance,the molding material can be regarded as a different material from theoriginal material. This holds also true for the case in which a moldedproduct is claimed to be meaningful as two separate molded parts byusing two perfectly identical molding materials.

A manufacturing apparatus, according to the present invention that canefficiently mold, in a single step, a molded product consisting of aplurality of molded parts part of whose at least two molded parts facesoutside of the molded product, is a rotary press having a rotatable turntable provided with a die having a die hole and holding upper and lowerpunches above and below the die so as to be vertically slidable, andbeing designed to compress molding materials supplied and charged intothe die by moving the upper and lower punches in mutually approachingdirections and pressing with the punch tips in a state inserted in thedie, the rotary press being characterized in comprising at least theupper punch or preferably both the upper and lower punches split into aplurality of punches, means for moving the plurality of split punchesand allowing manipulation of at least two of the plurality of splitpunches for compression operation, a first molding materialsupply-charging unit for supplying and charging a first molding materialinto a space in the die formed above the tip portion of the lower punchor formed by the tip portions of split punches of the lower punch, asecond molding material supply-charging unit for supplying and charginga second molding material into a space formed above and/or around thefirst molding material in the die, a precompression molding unit forcompression-molding at least one of the molding materials supplied andcharged and a main compression molding unit for compression-molding theentire molded product. The rotary press comprises, as necessary, aresidual molding material removal unit for removing residual moldingmaterial remaining on the lower punch and/or the temporary moldedproduct. That is, the apparatus can perform the steps of supplying andcharging a plurality of molding materials respectively into intendedgiven spaces, compression-molding at least one of the molding materialssupplied and charged and compression-molding the entire molded productas essential steps and may, as necessary, allow performing the step ofremoving residual molding material on the lower punch and/or thetemporary molded product. It should be noted that the space formed bythe tip portions of split punches of the lower punch split into aplurality of punches refers to a space formed by moving some of thesplit punches of the lower punch.

To prevent contamination between molding materials and ensure clearidentification between molded parts, it is preferred that individualmolding materials be compression-molded every time they are supplied andcharged. For this reason, it is preferred that the rotary press of thepresent invention be normally provided with material supply-chargingunits and precompression molding units as many as the materialsupply-charging units, in addition to a main compression molding unit.

It should be noted that main compression refers to a compressionoperation designed to finally and completely mold the entire moldedproduct that is carried out at high compression pressures. On the otherhand, precompression, as opposed to main compression, refers to allcompression operations carried out at some point before maincompression, and it is preferred that precompression be normallyperformed as temporary compression. Temporary compression denotescompression operation at low compression pressures. It should be notedthat precompression after supply of the last molding material isprecompression of the entire molded product, and temporary compressionis normally carried out.

When manufacturing a molded product consisting of a plurality of moldedparts part of whose two molded parts faces outside of the moldedproduct, for example, the rotary press of the present inventioncomprises a first molding material supply-charging unit for supplyingand charging a first molding material, a precompression molding unit forcompression-molding the first molding material, a second moldingmaterial supply-charging unit for supplying and charging a secondmolding material and a main compression molding unit forcompression-molding the entire molded product and comprises, asnecessary, a residual molding material removal unit for removing theresidual first molding material.

If there are a number of molded parts or if molding materials arelocalized in a complex manner within the final molded product, naturallythe number of molding material supply-charging units increases.Similarly, it is necessary to increase the number of precompressionmolding units for compression-molding molding materials and the numberof residual molding material removal units for removing residual moldingmaterials as necessary.

It can be said that the present invention is characterized particularlyin its embodiments that contain the step of supplying and charging, ontoa molding material or a molded product consisting thereof, anothermolding material. That is, the rotary press that can perform such a stepis particularly characteristic among the rotary presses of the presentinvention.

Further in addition to the present invention, a method and apparatus aredisclosed time that can efficiently localize molding materials in themolded product in the manufacturing step of supplying and chargingmolding materials. Among them is a provision of a method for pushing upa molded product (temporary molded product) into a molding material,further allowing the molded product to penetrate through the moldingmaterial and removing residual molding material on top, thus localizingthe molding material in a complicated manner and allowing easymanufacture of the molded product. Also included is use of lower splitpunches for reducing the amount of residual molding material remainingon the lower punch. That is, the present invention also discloses a setof upper and lower punches having a split punch structure, with each tipthereof being split into a plurality of punches, individual splitpunches being vertically slidable and at least two split punches beingmanipulatable for compression operation, in which at least one of thelower split punches is further split as opposed to the correspondingupper split punch, in which part or whole of a residual molding materialremaining on the lower punch can be rubbed and cut by a rubbing-cuttingplate as the split punch is raised and in which, unlike the lower punch,the upper punch does not have a split form intended for removing theresidual molding material by rubbing and cutting. The set is, in otherwords, a method for reducing a residual molding material in thecompression molding apparatus provided, above and below the die, withpunches having a split punch structure, with each tip thereof beingsplit into a plurality of punches, individual split punches beingvertically slidable, and at least two split punches being manipulatablefor compression operation, the method characterized in that at least oneof the lower split punches is further split as opposed to thecorresponding upper split punch and that part or whole of a residualmolding material remaining on the lower punch can be rubbed and cut by arubbing-cutting plate as the split punch is raised.

Next, a specific description is given of steps for manufacturing amolded product consisting of a plurality of molded parts part of whoseat least two molded parts faces outside of the molded product using therotary press of the present invention. It should be noted that temporarycompression is employed as precompression in the examples. While moldedproducts manufactured are shown with a plurality of molded partsindifferent colors, this is for purposes of convenience and clarity, andthis does not necessarily mean that molding materials of differentcolors are used as in the invention of molded products discussed later.

As a first example, a detailed description is given mainly withreference to FIG. 5. It should be noted that the molded product iscylindrical in shape consisting of two types of molding materials, withone of the molded parts surrounded by another, as shown in FIG. 1. Bothupper and lower punches used have a double structure in which the tipportion of one punch is completely enclosed by the tip portion of theother punch, as shown in FIG. 24A-1.

First, with a lower split punch 1B lowered below the turn table surface(FIG. 5A), a first molding material M1 is supplied into a first moldedpart space 200 above the lower split punch 1B within a die 2 (FIG. 5B).The lower split punch 1B is raised as necessary, discharging the excessfirst molding material M1 out of the die 2 and thus charging a givenamount into the space by rubbing and cutting (FIG. 5C). Then, an uppersplit punch 2B and the lower split punch 1B are moved in mutuallyapproaching directions for precompression, thus temporarily molding thefirst molding material M1 (FIG. 5D). Next, the lower punches are movedto a given position, with the temporary molded product from the firstmolding material M1 held on the lower split punch 1B (FIG. 5F). A secondmolding material M2 is supplied into a second molded part space 201above a lower punch 1A within the die 2 at a position where the upperend surface of the temporary molded product from the first moldingmaterial M1 is slightly lower than the turn table surface (FIG. 5G). Thelower punch or punches (the lower split punch 1A and/or the lower splitpunch 1B) are raised as necessary, discharging the excess second moldingmaterial M2 out of the die 2 and thus ensuring charging of a givenamount into the space by rubbing and cutting (FIG. 5H). Then, an uppersplit punch 2A is moved toward the lower split punch 1A such that partof the surface of the second molding material M2 is covered (FIG. 5I).Under this condition, the residual second molding material M2 on thetemporary molded product from the first molding material M1 is removed(FIG. 5J). In the next compression operation, compression by moving bothupper and lower split punches at the same speed is not preferred as thismay disturb the distribution of molding materials within the moldedproduct because of difference in density between the temporary moldedproduct from the first molding material M1 and the second moldingmaterial M2. For this reason, the first molding material M1 is coveredby moving the upper punch (the upper split punch 2B) toward the lowerpunch (FIG. 5K), and next the lower split punch 1A is moved toward theupper split punch 2A for precompression until the punch tip surface ofthe lower split punch 1A is aligned with the punch tip surface of thelower split punch 1B (FIG. 5L). Then, the upper punches (the upper splitpunches 2A and 2B) and the lower punches (the lower split punches 1A and1B) are moved respectively in mutually approaching directions forprecompression (temporary compression) of the temporary molded productsfrom the first molding material M1 and the second molding material M2 asnecessary, eventually followed by main compression (FIG. 5M). The stepshown in FIG. 5N is for unloading the completed molded product.

As a second example, a detailed description will be given below mainlywith reference to FIG. 7. The molded product is convex in shape, withonly the molded part making up the center portion projecting on oneside, as shown in FIG. 6. The punches used are the same type as thoseused in the first example.

First, with a lower split punch 3A lowered below the turn table surface(FIG. 7A), the first molding material M1 is supplied into a first moldedpart space 202 above the lower split punch 3A enclosed by a lower splitpunch 3B (FIG. 7B). The lower split punch 3A is raised as necessary,discharging the excess first molding material M1 out of the die 2 andthus ensuring charging of a given amount into the space by rubbing andcutting (FIG. 7C). Then, an upper split punch 4A and the lower splitpunch 3A are moved in mutually approaching directions for precompression(FIG. 7D), thus temporarily molding the first molding material M1.During or after temporary molding of the first molding material M1, theresidual first molding material M1 remaining on the lower split punch 3Bis removed (FIG. 7E). Next, with the temporary molded product from thefirst molding material M1 held by the lower split punches 3A and 3B, thesecond molding material M2 is supplied into a second molded part space203 above and around the temporary molded product from the first moldingmaterial M1 within the die 2 (FIG. 7G) by lowering the lower punch orpunches (both the lower split punches 3A and 3B or the lower split punch3B) (FIG. 7F). After part of the temporary molded product from the firstmolding material M1 is stuck into the second molding material M2, theexcess second molding material M2 is discharged out of the die 2 asnecessary, thus charging a given amount into the space by rubbing andcutting (FIG. 7H). It should be noted that the second molding materialM2 can be supplied after sufficiently lowering the lower split punch 3Bfirst such that the temporary molded product from the first moldingmaterial M1 is apparently pushed up. Then, the upper punches (the uppersplit punches 4A and 4B) and the lower punches (the lower split punches3A and 3B) are moved respectively in mutually approaching directions forprecompression (temporary compression) of the entire molded productconsisting of the first and second molding materials as necessary,eventually followed by main compression (FIG. 7I). The step shown inFIG. 7J is for unloading the completed molded product.

As a third example, a brief description is given next mainly withreference to FIG. 9. The molded product is that in which two types ofmolding materials are used in the first molded part portion in themolded product of the second example.

Although the third example is basically only a repetition of supply ofthe first molding material in the second example, the first moldingmaterial M1 need not always be compression-molded in FIGS. 9D and 9E,and it suffices to only slightly press the surface of the first moldingmaterial M1 with an upper split punch 6A in order to allow removal ofresidual molding material. To prevent contamination between the firstand second molding materials M1 and M2, however, it is preferred thatcompression molding of the first molding material M1 be carried out.

As a fourth example, a detailed description will be given below mainlywith reference to FIG. 11. The molded product is donut-shaped, with amolding material making up one of the surfaces of the cylindricalstructure also existing at the center portion of the molded product, asshown in FIG. 10. While the punches used are of the type in which thetip portion of one punch completely encloses the tip portions of otherpunches, as shown in FIG. 24B-1, the upper punches have a doublestructure with a hollow at the center while the lower punches a triplestructure with a split punch provided at the center. It should be notedthat a lower split punch 7C does not perform compression operation.

First, with a lower split punch 7B lowered below the turn table surface(FIG. 11A), the first molding material M1 is supplied into a firstmolded part space 204 above the lower split punch 7B enclosed by the die2 and a lower split punch 7A (FIG. 11B). The lower split punch 7B israised as necessary, discharging the excess first molding material M1out of the die 2 and thus ensuring charging of a given amount into thespace by rubbing and cutting (FIG. 11C). Then, an upper split punch 8Band the lower split punch 7B are moved in mutually approachingdirections for precompression (FIG. 11D), thus temporarily molding thefirst molding material M1. It should be noted that the tip surface ofthe lower split punch 7C is always level with the turn table unlessotherwise required and may allow compression operation even if fixed inthis state. Next, after temporary molding of the first molding materialM1, the residual first molding material M1 remaining on the lower splitpunch 7A is removed (FIG. 11E). With the temporary molded product fromthe first molding material M1 held on the lower split punch 7B, thesecond molding material M2 is supplied into a second molded part space205 above and inside the temporary molded product from the first moldingmaterial M1 within the die 2 (FIG. 11G) by lowering the lower punches(the lower split punches 7A and 7C or the lower split punches 7A, 7B and7C) (FIG. 11F). The lower split punch 7C is raised to its initialposition (FIG. 11H), discharging the excess second molding material M2out of the die 2 as necessary and thus ensuring charging of a givenamount into the space by rubbing and cutting (FIG. 11I). Then, the upperpunches (the upper split punches 8A and 8B) and the lower punches (thelower split punches 7A and 7B) are moved respectively in mutuallyapproaching directions for precompression (temporary compression) of theentire molded product consisting of the first and second moldingmaterials as necessary, eventually followed by main compression (FIG.11J). The step shown in FIG. 11K is for unloading the completed moldedproduct.

As a fifth example, a detailed description will be given below mainlywith reference to FIG. 13. The molded product consists of three types ofmolding materials, with a protrusion on both surfaces of a rectangularparallelepiped, as shown in FIG. 12. The punches used have a rectangulartip surface split into two, with a recess provided on one side forforming protrusions (FIG. 24 D-4).

First, with a lower split punch 9A lowered below the turn table surface(FIG. 13A), the first molding material M1 is supplied into a firstmolded part space 206 above the lower split punch 9A and enclosed by thedie 2 and a lower split punch 9B (FIG. 13B). The lower split punch 9A israised as necessary, discharging the excess first molding material M1out of the die 2 and thus ensuring charging of a given amount into thespace by rubbing and cutting (FIG. 13C). Then, an upper split punch 10Aand the lower split punch 9A are moved in mutually approachingdirections for precompression (FIG. 13D), thus temporarily molding thefirst molding material M1. During or after temporary molding of thefirst molding material M1, the residual first molding material M1remaining on the lower split punch 9B is removed (FIG. 13E). Next, thesecond molding material M2 is supplied (FIG. 13G) into a second moldedpart space 207 (FIG. 13F) above the temporary molded product from thefirst molding material held on the lower split punch 9A within the die2. The lower split punch 9A is raised as necessary, discharging theexcess second molding material M2 out of the die 2 and thus ensuringcharging of a given amount into the space by rubbing and cutting (FIG.13H). Then, the upper split punch 10A and the lower split punch 9A aremoved in mutually approaching directions for precompression (FIG. 13I),thus temporarily molding the second molding material M2 together withthe temporary molded product from the first molding material M1. Duringor after temporary molding of the second molding material M2 (and thefirst molding material M1), the residual second molding material M2remaining on the lower split punch 9B is removed (FIG. 13J). Further,with the lower punch or punches (the lower split punches 9A and 9B orthe lower split punch 9B) lowered, a third molding material M3 issupplied (FIG. 13L) into a third molded part space 208 (FIG. 13K) abovethe temporary molded products from the first and second moldingmaterials M1 and M2 and on the lower split punch 9B within the die 2.The excess third molding material M3 is discharged out of the die 2 asnecessary, thus ensuring charging of a given amount into the space byrubbing and cutting (FIG. 13M). Finally, the upper punches (the uppersplit punch 10A and an upper split punch 10B) and the lower punches (thelower split punches 9A and 9B) are moved in mutually approachingdirections for precompression (temporary compression) of the entiremolded product consisting of the first, second and third moldingmaterials, eventually followed by main compression (FIG. 13N). The stepshown in FIG. 130 is for unloading the completed molded product. Itshould be noted that it is possible for the first molding material M1 toproceed with the step of removing the residual first molding material bylightly pressing down the surface of the first molding material M1without precompression thereof.

As a sixth example, a detailed description will be given below mainlywith reference to FIG. 15. The molded product is, with one moldingmaterial split into four parts and localized on one of the disc-shapedsurfaces, as shown in FIG. 14. Both upper and lower punches used have asplit structure as shown in FIG. 24D-1, with one of the split puncheshaving a tip portion split into four parts by the other split punch—across-shaped split punch.

First, with a lower split punch 11B lowered below the turn table surface(FIG. 15A), the first molding material M1 is supplied into a firstmolded part space 209 enclosed by the die 2 and a lower split punch 11Aabove the lower split punch 11B (FIG. 15B). The lower split punch 11B israised as necessary, discharging the excess first molding material M1out of the die 2 and thus ensuring charging of a given amount into thespace by rubbing and cutting (FIG. 15C). Then, the upper split punch 12Band the lower split punch 11B are moved in mutually approachingdirections for precompression (FIG. 15D), thus temporarily molding thefirst molding material M1. After temporary molding of the first moldingmaterial M1, the residual first molding material M1 remaining on thelower split punch 11A is removed (FIG. 15E). With the temporary moldedproduct from the first molding material M1 held on the lower split punch11B, the second molding material M2 is supplied into a second moldedpart space 210 above and around the temporary molded product from thefirst molding material M1 within the die 2 (FIG. 15G) by lowering thelower punches (the lower split punches 11A and 11B or the lower splitpunch 11A) (FIG. 15F). The excess second molding material M2 isdischarged out of the die 2 as necessary, thus ensuring charging of agiven amount into the space by rubbing and cutting (FIG. 15H). Then, theupper punches (the upper split punches 12A and 12B) and the lowerpunches (the lower split punches 11A and 11B) are moved respectively inmutually approaching directions for precompression (temporarycompression) of the entire molded product consisting of the first andsecond molding materials as necessary, eventually followed by maincompression (FIG. 15I). The step shown in FIG. 15J is for unloading thecompleted molded product.

As a seventh example, a detailed description will be given below mainlywith reference to FIG. 17. The molded product is disc-shaped, with oneof the surfaces split into two parts along the diameter, as shown inFIG. 16. The punches used have a circular tip surface split into twoparts, as shown in FIG. 24D2.

First, with a lower split punch 13A lowered below the turn table surface(FIG. 17A), the first molding material M1 is supplied into a firstmolded part space 211 enclosed by the die 2 and a lower split punch 13Band above the lower split punch 13A (FIG. 17B). The lower split punch13A is raised as necessary, discharging the excess first moldingmaterial M1 out of the die 2 and thus ensuring charging of a givenamount into the space by rubbing and cutting (FIG. 17C). Then, the uppersplit punch 14A and the lower split punch 13A are moved in mutuallyapproaching directions for precompression (FIG. 17D), thus temporarilymolding the first molding material M1. During or after temporary moldingof the first molding material M1, the residual first molding material M1remaining on the lower split punch 13B is removed (FIG. 17E). Next, withthe temporary molded product from the first molding material M1 held bythe lower split punches 13A and 13B, the second molding material M2 issupplied into a second molded part space 212 above the temporary moldedproduct from the first molding material M1 and above the lower splitpunch 13B within the die 2 (FIG. 17G) by lowering the lower punch orpunches (both the lower split punches 13A and 13B or the lower splitpunch 13B) (FIG. 17F). The excess second molding material M2 isdischarged out of the die 2 as necessary, thus ensuring charging of agiven amount into the space by rubbing and cutting (FIG. 17H). Then, theupper punches (the upper split punches 14A and 14B) and the lowerpunches (the lower split punches 13A and 13B) are moved respectively inmutually approaching directions for precompression (temporarycompression) of the entire molded product consisting of the first andsecond molding materials as necessary, eventually followed by maincompression (FIG. 17I). The step shown in FIG. 17J is for unloading thecompleted molded product.

As an eighth example, a detailed description will be given below mainlywith reference to FIG. 19. The molded product is convex in shape, withthe center portion projecting and further the projecting portion and thebottom portion being made of the same molding material, as shown in FIG.18. The punches used are the same as those used in the first example.

First, with a lower split punch 15A lowered below the turn table surface(FIG. 19A), the first molding material M1 is supplied into a firstmolded part space 213 enclosed by a lower split punch 15B and above thelower split punch 15A (FIG. 19B). The lower split punch 15A is raised asnecessary, discharging the excess first molding material M1 out of thedie 2 and thus ensuring charging of a given amount into the space byrubbing and cutting (FIG. 19C). Then, the upper split punch 16A and thelower split punch 15A are moved in mutually approaching directions forprecompression (FIG. 19D), thus temporarily molding the first moldingmaterial M1. During or after temporary molding of the first moldingmaterial M1, the residual first molding material M1 remaining on thelower split punch 15B is removed (FIG. 19E). Next, with the temporarymolded product from the first molding material M1 held on the lowersplit punch 15A, the second molding material M2 is supplied into asecond molded part space 214 above and around the temporary moldedproduct from the first molding material M1 within the die 2 (FIG. 19G)by lowering the lower punch or punches (both the lower split punches 15Aand 15B or the lower split punch 15B) (FIG. 19F). After part of thetemporary molded product from the first molding material M1 is stuckinto the second molding material M2 (FIG. 19H), the excess secondmolding material M2 is discharged out of the die 2 as necessary, thusensuring charging of a given amount into the space by rubbing andcutting (FIG. 19I). It should be noted that the second molding materialM2 can be supplied after sufficiently lowering the lower split punch 15Bfirst such that the temporary molded product from the first moldingmaterial M1 is apparently pushed up. Then, the upper split punch 16B andthe lower split punch 15B are moved respectively in mutually approachingdirections for precompression of the second molding material (FIG. 19J)followed by raising of the upper punch, thus removing the second moldingmaterial M2 remaining on the temporary molded product from the firstmolding material M1 (FIG. 19K). In the removal of the molding material,only the uncompressed second molding material M2 on the temporary moldedproduct from the first molding material M1 is removed while otherportions remain unremoved because they have been compression-molded.Next, the third molding material M3 is supplied into a third molded partspace 215 above the temporary molded products from the first and secondmolding materials M1 and M2 within the die 2 (FIG. 19M). The excessthird molding material M3 is discharged out of the die 2 as necessary,thus ensuring charging of a given amount into the space by rubbing andcutting (FIG. 19N). Then, the upper punches (the upper split punches 16Aand 16B) and the lower punches (the lower split punches 15A and 15B) aremoved respectively in mutually approaching directions for precompression(temporary compression) of the entire molded product consisting of thefirst, second and third molding materials as necessary, eventuallyfollowed by main compression (FIG. 190). The step shown in FIG. 19P isfor unloading the completed molded product.

It should be noted that although the same material is used for the thirdmolding material M3 as for the first molding material M1, thesematerials are described as separate materials for reasons ofconvenience. It is of course possible to use a completely differentmolding material for the third molding material M3 from those of thefirst and second molding materials M1 and M2.

It should be also noted that a method is provided in the eighth examplefor localizing a molding material in a complex manner and allowing easymanufacture of the molded product by pushing up a temporary moldedproduct into the molding material, allowing the molded product topenetrate through the molding material and thereby removing the residualmolding material on top, as shown in FIGS. 19G to 19L, as a method forefficiently localizing molding materials in a molded product. The methodis possible only if a residual molding material removal device isavailable, and a detailed description thereof will be given later.

As a ninth example, a detailed description will be given below mainlywith reference to FIG. 21. The molded product is disc-shaped, with twomolded parts provided on the right and left sides separately from eachother, as shown in FIG. 20. The punches used are the same as those usedin the seventh example.

First, with a lower split punch 17A lowered below the turn table surface(FIG. 21A), the first molding material M1 is supplied into a firstmolded part space 216 enclosed by a lower split punch 17B and the die 2and above the lower split punch 17A (FIG. 21B). The lower split punch17A is raised as necessary, discharging the excess first moldingmaterial M1 out of the die 2 and thus ensuring charging of a givenamount into the space by rubbing and cutting (FIG. 21C). Then, the uppersplit punch 18A and the lower split punch 17A are moved in mutuallyapproaching directions for precompression (FIG. 21D), thus temporarilymolding the first molding material M1. During or after temporary moldingof the first molding material M1, the residual first molding material M1remaining on the lower split punch 17B is removed (FIG. 21E). Next, withthe temporary molded product from the first molding material M1 held bythe lower split punches 17A and 17B, the second molding material M2 issupplied into a second molded part space 217 above the temporary moldedproduct from the first molding material M1 within the die 2 (FIG. 21G)by lowering the lower punch or punches (both the lower split punches 17Aand 17B or the lower split punch 17B) (FIG. 21F). The excess secondmolding material M2 is discharged out of the die 2 as necessary, thusensuring charging of a given amount into the space by rubbing andcutting (FIG. 21H). Further, the second molding material M2 remaining onthe surface of the temporary molded product from the first moldingmaterial M1 on the lower split punch 17A is removed, with the chargedsecond molding material M2 lightly covered by an upper split punch 18B(FIG. 21I). Then, the upper split punch 18A is lowered onto the moldedproduct such that the tips of the upper split punches are aligned witheach other, followed by precompression of the second molding material M2by the lower split punch 17B and the upper split punch 18B (FIG. 21J).Further, the upper punches (the upper split punches 18A and 18B) and thelower punches (the lower split punches 17A and 17B) are movedrespectively in mutually approaching directions for precompression(temporary compression) of the entire molded product consisting of thefirst and second molding materials as necessary, eventually followed bymain compression (FIG. 21K). The step shown in FIG. 21L is for unloadingthe completed molded product.

It should be noted that the residual molding material removal step canbe carried out by compressed air injection and suction (device shown inFIG. 33), brushing, scraper, etc. or a device equipped with acombination thereof in any one of the embodiments. A detaileddescription will be given later. It should be also noted that, dependingon the punch shapes, the residual molding material removal step can becarried out concurrently with the compression step in some cases whilethe step can only be performed at the completion of the compression stepin other cases. If the compression step is skipped, the residual moldingmaterial removal step is carried out with the surface of the moldingmaterial lightly pressed down by the punch.

While the embodiments requiring the residual molding material removalstep have been described so far, an embodiment not requiring the stepwill be presented next. As a tenth example, a detailed description willbe given below mainly with reference to FIG. 35. The molded product iscylindrical in shape and made up of two types of molding materials, withone of the molded parts making up one of the surfaces and the core ofthe molded product surrounded by the other molded part, as shown in FIG.34. Both upper and lower punches used have a double structure in whichthe tip portion of one punch is completely enclosed by the tip portionof the other punch, as shown in FIG. 24A-1.

First, with a lower split punch 21B lowered below the turn table surface(FIG. 35A), the first molding material M1 is supplied into a firstmolded part space 220 above a lower split punch 21B within the die 2(FIG. 35B). The lower split punch 21B is raised as necessary,discharging the excess first molding material M1 out of the die 2 andthus ensuring charging of a given amount into the space by rubbing andcutting (FIG. 35C). Then, an upper split punch 22B and the lower splitpunch 21B are moved in mutually approaching directions forprecompression, thus temporarily molding the first molding material M1(FIG. 35D). Next, the lower punches are moved to a given position, withthe temporary molded product from the first molding material M1 held onthe lower split punch 21B (FIG. 35F). The second molding material M2 issupplied into a second molded part space 221 above a lower punch 21A andabove the temporary molded product from the first molding material M1within the die 2 at a position where the upper end surface of thetemporary molded product from the first molding material M1 is slightlylower than the turn table surface (FIG. 35G). The lower punch or punches(the lower split punch 21A and/or the lower split punch 21B) are raisedas necessary, discharging the excess second molding material M2 out ofthe die 2 and thus ensuring charging of a given amount into the space byrubbing and cutting (FIG. 35H). In the next compression operation,compression by moving both upper and lower split punches at the samespeed is not preferred as this may disturb the distribution of moldingmaterials within the molded product because of difference in densitybetween the temporary molded product from the first molding material M1and the second molding material M2. For this reason, the first moldingmaterial M1 is covered by moving the upper punches (an upper split punch22A and the upper split punch 22B) toward the lower punches, and nextthe lower split punch 21A is moved toward the upper split punch 22A forprecompression until the punch tip surface of the lower split punch 21Ais aligned with the punch tip surface of the lower split punch 21B (FIG.35I). Further, the upper punches (the upper split punches 22A and 22B)and the lower punches (the lower split punches 21A and/or 21B) are movedin mutually approaching directions for precompression (temporarycompression) of the temporary molded products from the first and secondmolding materials M1 and M2, eventually followed by main compression(FIG. 35J). The step shown in FIG. 35K is for unloading the completedmolded product.

As an eleventh example, a detailed description will be given belowmainly with reference to FIG. 37. The molded product is donut-shaped,with a molding material making up one of the surfaces of the cylindricalstructure also existing at the center portion of the molded product, asshown in FIG. 36. While the punches used are of the type in which thetip portions of other punches are completely enclosed by the tip portionof one punch, as shown in FIG. 24B-1, the upper punches have a doublestructure with a hollow at the center. The lower punches have a triplestructure with a split punch also provided at the center. It should benoted that a lower split punch 23C does not perform compressionoperation.

First, with a lower split punch 23B lowered below the turn table surface(FIG. 37A), the first molding material M1 is supplied into a firstmolded part space 222 enclosed by the die 2 and a lower split punch 23Aand above the lower split punch 23B (FIG. 37B). The lower split punch23B is raised as necessary, discharging the excess first moldingmaterial M1 out of the die 2 and thus ensuring charging of a givenamount into the space by rubbing and cutting (FIG. 37C). Then, an uppersplit punch 24B and the lower split punch 23B are moved in mutuallyapproaching directions for precompression (FIG. 37D), thus temporarilymolding the first molding material M1. It should be noted that the tipsurface of the lower split punch 23C is always level with the turn tableunless otherwise required and may allow compression operation even iffixed in this state. Next, with the temporary molded product from thefirst molding material M1 held on the lower split punch 23B, the secondmolding material M2 is supplied into a second molded part space 223above and inside the temporary molded product from the first moldingmaterial M1 within the die 2 (FIG. 37F) by lowering the lower punches(the lower split punches 23A and 23C or the lower split punches 23A, 23Band 23C) (FIG. 37E). The lower split punch 23C is raised to its initialposition (FIG. 37G), discharging the excess second molding material M2out of the die 2 as necessary and thus ensuring charging of a givenamount into the space by rubbing and cutting (FIG. 37H). Then, the upperpunches (an upper split punch 24A and the upper split punch 24B) and thelower punches (the lower split punches 23A and 23B) are movedrespectively in mutually approaching directions for precompression(temporary compression) of the entire molded product consisting of thefirst and second molding materials as necessary, eventually followed bymain compression (FIG. 37I). The step shown in FIG. 37J is for unloadingthe completed molded product.

From here, a description will be further given of the case in which anormal punch not having a split punch structure is used as the lowerpunch. The present embodiment will be explained below in detail as atwelfth example mainly with reference to FIG. 41. The molded product iscylindrical in shape, with the center portion of a molded part making upone of the surfaces projecting outward and the molded part furtherprojecting into the molded product toward the center thereof, as shownin FIG. 42B. While the punches used are of the type in which the tipportion of one punch is completely enclosed by the tip portion of theother punch, as shown in FIG. 24A-1, the upper punch has a doublestructure while a normal punch with no split structure is used as thelower punch.

First, with a lower punch 25A lowered below the turn table surface (FIG.41A), the first molding material M1 is supplied into a first molded partspace 224 enclosed by the die 2 and the lower punch 25A and above alower split punch 25B (FIG. 41B). The lower punch 25A is raised asnecessary, discharging the excess first molding material M1 out of thedie 2 and thus ensuring charging of a given amount into the space byrubbing and cutting (FIG. 41C). Then, with an upper split punch 26Aprojecting beyond an upper split punch 26B, the upper split punches 26Aand 26B and the lower punch 25A are moved in mutually approachingdirections for precompression (FIG. 41D), thus temporarily molding thefirst molding material M1. Next, with the temporary molded product fromthe first molding material M1 held on the lower punch 25A, the secondmolding material M2 is supplied into a second molded part space 225above the temporary molded product from the first molding material M1within the die 2 (FIG. 41F) by moving the lower punch 25A to a givenposition (FIG. 41E). The lower punch 25A is raised to a given positionas necessary, discharging the excess second molding material M2 out ofthe die 2 and thus charging a given amount into the space by rubbing andcutting (FIG. 41G). Then, with the upper split punch 26B projectingbeyond the upper split punch 26A, the upper punches and the lower punch25A are moved in mutually approaching directions for precompression(temporary compression) of the entire molded product consisting of thefirst and second molding materials as necessary, eventually followed bymain compression (FIG. 41M). The step shown in FIG. 41N is for unloadingthe completed molded product.

Manufacturing steps have been described so far in relation to variousembodiments of the method for manufacturing a molded product consistingof a plurality of molded parts part of whose at least two molded partsfaces outside of the molded product using the rotary press of thepresent invention. The rotary press of the present invention isconstructed to allow performance of the manufacturing steps in order tomanufacture a molded product consisting of a plurality of molded partspart of whose at least two molded parts faces outside of the moldedproduct. From here onwards, conventional rotary press will be describedfirst followed by a detailed description of structural portions of themanufacturing apparatus which is the rotary press of the presentinvention.

If shaft-driven, for example, rotary press often has a vertical shaft58, supported by a bearing 57, arranged at the center portion of a mainbody frame 56, with a motor 59 transmitting rotational drive force tothe vertical shaft and a turn table 1 fixed near the vertical shaft(FIG. 23). Further, there are provided an upper punch holding portion60, located on the upper portion of the turn table 1, for holding anupper punch so as to be vertically slidable and a lower punch holdingportion 61, located on the lower portion of the turn table 1, forholding a lower punch so as to be vertically slidable such that the turntable 1 is sandwiched between the upper and lower punch holding portions60 and 61. On the turn table 1, there is a die portion made up of aplurality of a die mounting hole 62, for fitting the die 2 so as to beslidable, that are provided along the same circumference. On each of theupper and lower punch holding portions 60 and 61, there are a pluralityof punch holding hole 63 drilled for holding the upper and lower punchesso as to be slidable. Each of the punch holding hole 63 and the diemounting hole 62 is drilled on the turn table such that the lower punch64, the upper punch 65 and the die 2 are arranged vertically with theircenter lines aligned. Tracks 66 are provided correspondingly for trackcontact portions of the upper punch 65 and the lower punch 64, and thepunches move vertically on the tracks as they engage with and are guidedby respective cams which will be discussed later. The die 2 has a diehole 67 cut vertically through the die into which the tips of the upperand lower punches 65 and 64 are inserted. It should be noted that 68represents a compression roller while 69 a hopper in FIG. 23. Inaddition to shaft-driven rotary press, there are other types of rotarypresses such as external gear-driven (external gear type) rotary pressin which rotational drive force is transmitted by equipping the turntable with a gear and also internal gear-driven (internal gear type)rotary press.

Next, a description will be given of the punches having a multi-splitstructure used in the present invention and the portions associatedtherewith.

The rotary press of the present invention is constructed to have atleast the upper punch or preferably both upper and lower punches splitinto a plurality of punches. Various split forms of the punch tipportions are shown in FIG. 24. For instance, FIG. 24A illustratepunches, each of which consists of two split punches with the tipportions thereof also split into two parts and in which the tip portionof one punch is completely enclosed by the tip portion of the otherpunch. FIG. 24B illustrate punches, each of which consists of two ormore split punches with their tip portions also split into three or moreparts and in which the tip portion of one punch completely encloses thetip portions of other punches. FIG. 24C illustrate punches, each ofwhich consists of two or more split punches and in which the tipportions of at least two punches are not completely enclosed by the tipportion of other punch. FIG. 24D illustrate punches, each of whichconsists of two or more split punches and in which the tip portions ofnone of the punches are enclosed by the tip portion of other punch. Itis to be understood that while some of the punches of FIGS. 24B to 24Dconsist of the same number of split punches as the number of divisionsof the tip portion, others take on the form in which only the tipportion of one split punch is split further. Although the aforementionedforms represent typical split forms of the punch tip portions, splitforms are not limited thereby.

While individual split punches that are separate from one anothercommonly take on the split form in which the upper and lower punches canperform compression in a mutually responsive fashion, the split patternsof the upper and lower punches do not necessarily need to coincide witheach other, and the number of divisions and the split shapes of theupper and lower punches may differ from each other. The split patternsof the upper and lower punches are changed for different reasonsincluding changing the split shapes in accordance with the target moldedproduct shape or the arrangement of a plurality of individualingredients and splitting the lower punch further to reduce the amountof residual molding materials. Among specific examples are the upper andlower punches in which one of the split punches encloses the other splitpunch or punches as shown in FIG. 26A with the upper punch split intotwo parts and the lower punch into three parts, those in which while theupper punch is only split into two semicircles, one of the semicirclesof the lower punch is further split into two punches as shown in FIG.26B and those used for example in FIG. 11 in which the upper punch has adouble structure with a hollow at the center while the lower punch has atriple structure with no hollow. In any case, the number of divisionsand the split shapes are not limited so long as the upper and lowerpunches can perform compression operation in the compression step usingindividual split punches making up the upper and lower punches and thecombination thereof. Alternatively, it is possible to manipulate themolded product shape by using the lower punch with no split structureand the upper punch with a split structure.

A description will be given of the upper and lower punches both having asplit structure but differing in split shape mainly with reference toFIG. 26. FIG. A-1 shows an upper punch, FIG. A-2 a lower punch and FIG.A-3 a sectional view of the punch tips when the upper and lower punchesof FIGS. A-1 and A-2 are brought close to each other in the conditionadhering to the actual usage (shading representing cross sectionomitted). The same holds true for FIGS. B-1 to B-3. In this case, themain purpose of having different split shapes for the upper and lowerpunches lies in reducing the amount of residual molding material on thelower punch rather than localizing the molding material. To reduce theamount of residual molding material on the lower punch, the lower punchis split into more parts than the upper punch, thus reducing theresidual molding material on the lower punch not removable with therubbing-cutting plate. For instance, FIGS. 26A-1 to 26A-3 correspond toFIG. 22(2). As is apparent from comparison between FIG. 22(1) and FIG.22(2), a split punch is used for the portion capable of forming the sameplane as the turn table, allowing removal of excess molding materialfrom the portions by the rubbing-cutting plate as the split punch israised to the same plane as the turn table and thereby reducing theabsolute amount of residual molding material. Here, the two punch tipportions (20B1, 20B2) for removing excess molding material make up asingle split punch. Further, if the punch tips consist entirely ofcurving surfaces as shown in FIGS. 26B-1 to 26B-3, it is impossible forthe lower punch to form the same plane as the turn table. However,removal of excess molding material by the rubbing-cutting plate ispossible by raising some of the lower split punches to the proximity ofthe turn table, thus reducing the absolute amount of residual moldingmaterial. That is, the present method for splitting punches does notrequire the lower punch to take on the split form that allows formationof the same plane as the turn table. It suffices to use the split formthat allows reduction of the absolute amount of residual moldingmaterial by the rubbing-cutting plate, and the number of divisions isnot specifically limited. For example, the lower punch shown in FIGS.26B-1 to 26B-3 consists of three split punches, with the split form notbeing evenly split with respect to the longer diameter. The reason isthat if the purpose is to remove molding material remaining on one ofthe split punches, then splitting the other split punch further orevenly splitting the lower punch is meaningless (FIG. 17D, FIG. 21D).

Split punches used in the present invention can be grouped under fivetypes in terms of split form of the upper and lower punches as follows.(1) Both of the upper and lower punches consist of two split punches,with the tip portion of one of the split punches completely enclosingthe tip portion of the other punch. (both upper and lower punches with adouble structure) (2) Either of the upper and lower punches consists ofthree or more split punches, with the tip portion of one of the splitpunches completely enclosing the tip portions of the other punches. (3)At least two of the tip portions of either of the upper and lowerpunches are not completely enclosed by the other split punches. (4) Thetip portions of none of the punches of both the upper and lower punchesare enclosed by the tip portions of the other punches. (5) The lowerpunch is a normal punch with no split structure.

A description has been given so far focusing on punch split forms.Diversity of molded products will be described below that can bemanufactured by the rotary press of the present invention and theaforementioned punches. As is evident from the punch split forms andpunch structures, punches consisting of a single split form are capableof manufacturing a variety of molded products of different forms. Thereason is that while shape change beyond the die inner diameter isimpossible as with common presses, variations can be added to moldedproducts, as far as the vertical direction with respect to the punchsurface is concerned, by the amount and type of molding materialcharged, or repetition thereof or the method for setting a space intowhich molding material is to be charged. Further, the respective splitpunches of the punches in the rotary press of the present inventionhaving a split punch structure are slidable and at least two thereof aremanipulatable for compression operation, considerably enhancingvariations as compared with conventional non-split punches.

One of such examples is shown in FIG. 25. FIG. 25A illustrates a punchtip surface in which the tip portion of one of the punches completelyencloses the tip portion of the other punch (same as FIG. 24A-1). Next,FIGS. 25B-1 to 25E-2 show modes of the molded products that can bemanufactured with the punch having the split form. Those shown in FIGS.25B-1 to 25B-3 are molded products consisting of a plurality of moldedparts with no concave or convex structure on either of the surfaces ofthe cylindrical structure. In detail, these figures show: a moldedproduct in which the molding material located at the center stretches toboth surfaces of the cylinder (25B-1, same as FIG. 1); another moldedproduct in which the molding material stretches to only one of thecylinder surfaces (25B-2) and still another molded product in which themolding material stretches to both surfaces of the cylinder but isseparated within the molded product (FIG. 25B-3). FIGS. 25C-1 to 25C-3show molded products consisting of a plurality of molded parts with aconvex structure on one of the surfaces of the cylindrical structure: amolded product in which a molding material located at the centerstretches to the opposite surface of the cylinder (25C-1); anothermolded product in which the molding material stops halfway within thecylindrical molded product (25C-2) and still another molded product inwhich the molding material exists only on top of the cylindrical moldedproduct (25C-3). FIGS. 25D-1 and 25D-2 show molded products consistingof a plurality of molded parts with a convex structure on both surfacesof the cylindrical structure: a molded product in which a moldingmaterial located at the center stretches to the opposite surface of thecylinder (25D-1) and another molded product in which the moldingmaterial exists on both surfaces but is separated within the cylindricalmolded product (25D-2). FIGS. 25E-1 and 25E-2 show molded productsconsisting of a plurality of molded parts with a concave structure oneither of the surfaces of the cylindrical structure: a molded product inwhich a molding material located at the center stops halfway within themolded product (25E-1) and another molded product in which the othersurface has a convex structure consisting of the same molding material.In addition to the above, a variety of other molded products can bemanufactured such as those having a concave structure on both surfacesand that including three or more molding materials. Thus, punches madeup of a single split form are capable of manufacturing a variety ofmolded products of different forms, and this holds true for all otherpunches shown in FIG. 24.

It is to be understood that there are also a considerably large numberof variations in moldable molded products in particular in the case ofthe lower punch being a normal punch with no split structure. Oneexample is shown in FIG. 42. These molded products are also shaped insuch a manner as to combine large and small cylindrical structures andconsist of a plurality of molded parts with a convex or concavestructure on either of the surfaces as with the aforementioned moldedproducts. In detail, FIG. 42A show a molded product that has a combinedstructure of a cylindrical molded part with a convex structure on one ofthe surfaces and another cylindrical molded part with no concave orconvex structure. FIG. 42B show a molded product that, although having astructure similar to that of FIG. 42A, has a cylindrical molded partwith a convex structure further having a convex structure on thejunction surface within the molded product. FIG. 42C show a moldedproduct that consists of a cylindrical molded part with a concavestructure on one of the surfaces of the cylindrical structure andanother cylindrical molded part with no concave or convex structure.FIG. 42D show a cylindrical molded product that has a three-layerstructure in which a molded part is added on top of the molded productof FIG. 42A and has no concave or convex structure as a whole.

In the present invention, it is absolutely essential that all individualsplit punches making up a punch be slidable and that at least two of thesplit punches making up a punch be manipulatable for compressionoperation. As an example, a punch is shown in FIG. 27 that correspondsto the series of punches in FIG. 24A and consists of two split punchesin which the tip portion of one of the punches completely encloses thetip portion of the other punch. It is to be noted that, from hereonwards, the split punches are called split A and B punches forconvenience. The punch comprises a split A punch 3A, a split B punch 3B,a split A punch compression head (substantially the same location as thebottom portion of the split A punch) 25, a split B punch compressionhead 70 and a split B punch vertical sliding motion adjustment roller23. The compression step is carried out by pressing the split A punchcompression head 25 with compression rollers (29, 31, 35 in FIG. 32) andfurther by pressing the split B punch compression head 70 withcompression rollers (33, 37 in FIG. 32). Manipulation of the split A andB punches for compression operation is thus achieved. It is to be notedthat the portions of the split A and B punches in contact with thecompression rollers (the split B punch compression head 70 and the splitA punch compression head 25) are separated vertically, thus preventingthe compression rollers for the split A and B punches from interferingwith one another.

While the vertical sliding motion of the split A punch is controlled bya normal method mainly using a split A punch track and the bottomportion thereof (split A punch compression head) 25, the verticalsliding motion adjustment roller 23 is provided that comes in directcontact with a split B punch track to allow vertical sliding motion ofthe split B punch. Preferably, a plurality of bearings 71 are providedwithin the rollers to allow rotation of the rollers and smooth verticalsliding motion of the split B punch. Here, the vertical sliding motionadjustment roller 23 is arranged outside the split B punch compressionhead 70, with the vertical sliding motion adjustment roller 23 separatedfrom the split B punch compression head 70. This allows the compressionrollers to apply pressure only to the split B punch compression head 70while not applying direct pressure to the vertical sliding motionadjustment roller 23, thus preventing breakage of the bearings 71 withinthe vertical sliding motion adjustment roller 23. In compressionoperation, it is possible to apply pressure to the outer punch more fromthe side of the center punch, thus allowing efficient transfer ofpressure from the compression rollers to the molding materials.

While FIG. 27 assume the lower punch, the basic structure is the samefor the upper punch. Among differences between the upper and lowerpunches are a longer length of the tip portion of the lower punchinserted into the die and different portions prescribing the punchmotion (e.g., spaces within the punches) due to different motions of theupper and lower punches.

There is a possibility that the aforementioned punch may have a form inwhich the motions of the split A and B punches are respectivelycontrolled in reverse. That is, the punch controls the motion of thesplit A punch with the vertical sliding motion adjustment roller and thetrack and the motion of the split B punch with the punch bottom portion(same location as the compression head 72 of the split B punch) and thetrack. The punch is characterized in that an opening (a split B punchopening 73) is provided on the main body of the split B punch and that asplit A punch compression head 74 integral with the split A punch and asplit A punch vertical sliding motion adjustment roller 75 project fromthe opening. A description of the punch will be omitted since the sameholds true for the punch as for the punch of FIG. 27, except that themotions of the split A and B punches are respectively controlled inreverse.

FIG. 29 show, as an example of other form of split punches, anembodiment of the punch whose cross section is split into twosemicircular punches in which neither of the split punches are enclosedby the other split punch, which corresponds to the punch of FIG. 24D-2.The punch conforms to the basic structure of the punch shown in FIG. 27except that the tip portion of the punch is not enclosed by other splitpunches. The punch also comprises a split A punch 22A, a split B punch22B, a split A punch compression head 76, a split B punch compressionhead 77, a split B punch vertical sliding motion adjustment roller 78and others and adopts a similar system for the mechanism controlling thevertical sliding motions and manipulation of the split A and B punchesfor compression operation.

In addition, as for the punch whose tip portion is shaped as shown inFIG. 24D-1 for pressing the molded product shapes as shown in FIG. 14,the tip portions of both the upper and lower split punches 12B and 11Bas shown in FIG. 15 are split into four parts. However, since thesefour-part tip portions do not need to perform sliding motion andcompression individually, each has an integral structure at the shellportion thereof as the upper split punch 12B or the lower split punch11B, thus allowing sliding motion and compression integrally. Such astructure, known as so-called “multiple punch” (double punch, sextuplepunch) and employed in wide-ranging fields including drugs, is basicallyidentical in terms of structure to those punches in which only the tipportion is split into a plurality of parts.

Next, FIG. 30 show, as still another form of split punches, anembodiment of the punch that has a triple split punch structure in whichthe punch is split into three parts, which corresponds to the punch ofFIG. 24B-1. While the punch conforms to those punches shown in FIGS. 27to 29 in terms of basic structure with the majority of the structurebeing similar, manipulation for compression operation and verticalsliding motion of a split C punch located at the centermost portion arecontrolled by other portion. The punch comprises split A, B and Cpunches 23A, 23B and 23C, split A, B and C punch compression heads 79,80 and 81 and split B and C punch vertical sliding motion adjustmentrollers 82 and 83. The compression step is carried out by pressing thesplit A, B and C punch compression heads 79, 80 and 81 with compressionrollers of the press. It is to be noted that since the split A and Cpunch compression heads 79 and 81 are in proximity of each other, it isnecessary to set the positions of the compression rollers of the pressso as to prevent contact points (positions) between the compressionrollers and the split A and C punches from interfering with each otherin order to allow compression operation in the independent compressionstep. For compression by the split A punch, for example, the compressionroller positions are adjusted such that the edge portion of the split Apunch compression head comes in contact with the compression rollers toachieve compression. For compression by the split C punch, on the otherhand, it is possible to prevent interference between the split A and Cpunches in the compression step by reducing the compression rollerwidth. Alternatively, interference by the compression rollers can beavoided by moving the split A and C punches toward either side ratherthan locating them at the center as in the split C punch compressionhead position in FIG. 30 and thereby securing a distance between thecontact point between the split A punch and the compression roller andthat between the split C punch and the compression roller (not shown).It may be also possible to prevent interference between individual splitpunches in the compression step by adjusting the positions of both therollers and the punch compression heads. Manipulation of the split A, Band C punches for compression operation is achieved by such a structure.While the vertical sliding motion of the split A punch is controlled bya normal method mainly using the split A punch track and the split Apunch bottom portion 79 (same location as the split A punch compressionhead 79), the vertical sliding motion adjustment roller 82 is providedthat comes in direct contact with the split B punch track to allowvertical sliding motion of the split B punch. The vertical slidingmotion mechanism of the split C punch is similar to that of the split Bpunch.

Next, a description will be given in detail of an embodiment of theapparatus corresponding to the second embodiment of the manufacturingmethod of the present invention (FIG. 7) together with operations of theportions thereof mainly with reference to FIGS. 31 and 32 and, asnecessary, FIG. 7 as the apparatus of the present invention that is therotary press for manufacturing a molded product consisting of aplurality of molded parts part of whose at least two molded parts facesoutside of the molded product.

When looked from above the turn table as shown in FIG. 31, moldingmaterial supply portions 3 and 4, molding material charging units 5 and6, molding material rubbing-cutting portions 7 and 8, compressionmolding units 9, 10 and 11, a residual molding material removal unit 12and a product unloading portion 13 are provided along the direction ofrotation of the turn table 1. Individual mechanisms will be describedseparately below.

The molding material supply portions 3 and 4 can be separated, accordingto the sequence of supply of molding materials, into the portion 3 forsupplying the first molding material M1 and the portion 4 for supplyingthe second molding material M2, with the molding materials supplied bynatural fall or by a metered supply machine (not shown) from hoppers 14and 15 filled with the respective molding materials.

The respective molding materials supplied by the molding material supplyportions are then sent next to the molding material charging units 5 and6. The molding material charging units are designed to charge the firstand second molding materials M1 and M2, used as molding materials forthe first and second molded parts, respectively into the first andsecond molded part spaces 202 and 203 (refer to FIG. 7). These portionsare intended to hold fixed amounts of the respective molding materialssupplied from the molding material supply portions using open feed shoes16 and 17, provided on the turn table 1 and capable of both storing andsupplying the molding materials, and introduce the molding materialsheld by the feed shoes 16 and 17 into the first and second molded partspaces 202 and 203 (refer to FIG. 7) by lowering the lower split A punch3A using lowerers 19 and 20 provided on a frame 18, and in certaincircumstances, by lowering the lower split B punch 3B using a lowerer 22provided on a lower split B punch track 21. Although the open feed shoes16 and 17 are shown in FIG. 31, agitation feed shoes may be employedthat forcefully charge the molding materials into the die 2 usingagitation vanes (installed at the same positions as the open feed shoes;not shown).

In detail, the first molding material is charged by lowering the lowersplit A punch 3A within the first open feed shoe 16 on the turn table 1(FIGS. 7A and 7B). The lower split B punch 3B is maintained at aconstant height with respect to the turn table by moving the lower splitB punch 3B on the lower split B punch track 21 installed so as to bringthe extreme tip portion of the lower split B punch to the same height asthe surface of the turn table 1 using the vertical sliding motionadjustment roller 23 of the lower outer punch. On the other hand, thelower split A punch 3A is moved on a lower split A punch track 24provided on the frame 18 using the lower split A punch bottom portion 25(same location as the lower split A punch compression head) and furtheradjusted to a predetermined position using the first lower split A punchlowerer 19 provided on the lower split A punch track 24. The firstmolding material M1 for the first molded part is thus introduced intothe first molded part space 202 enclosed by the lower split B punch 3Band above the lower split A punch 3A.

Next, the second molding material M2 is charged by lowering both thelower split A punch 3A holding the temporary molded first molded partand the lower split B punch 3B or only the lower split B punch 3B withinthe second open feed shoe 17 on the turn table 1 (FIGS. 7F and G). Here,the lower split B punch 3B is lowered by using the lower split B punchlowerer 22 provided on the lower split B punch track 21. On the otherhand, the lower split A punch 3A is moved on the lower split A punchtrack 24 provided on the frame 18 using the lower split A punch bottomportion 25 (same location as the compression head of the lower split Apunch) and lowered using the second lower split A punch lowerer 20provided on the lower split A punch track 24. The second moldingmaterial M2 is thus introduced by lowering both the lower split A punch3A holding the temporary molded first molded part and the lower split Bpunch 3B or only the lower split B punch 3B into the second molded partspace 203 created above and around the first molding material M1 withinthe die 2.

The die and the punches charged with the molding materials by themolding material charging units next enter the molding materialrubbing-cutting portions 7 and 8. The molding material rubbing-cuttingportions adjust the first and second molding materials M1 and M2supplied and charged as described above to fixed amounts. That is, therespective excess molding materials overflowing from the given spacesare rubbed and cut for removal by rubbing-cutting plates 26 and 27 asthe lower split A punch 3A or both the lower split A and B punches 3Aand 3B are raised to predetermined positions.

In detail, the first molding material M1 is rubbed and cut by therubbing-cutting plate 26 attached to the first open feed shoe 16 on theturn table 1. With the extreme tip portion of the lower split B punch 3Bleveled with the turn table, the lower split A punch 3 a is raised to apredetermined position using the lower split A punch track 24 and thelower split A punch lowerer 19, thus causing the excess amount of thefirst molding material M1 charged into the first molded part space 202to overflow from the space. Further, the overflowing first moldingmaterial M1 is rubbed and cut by the rubbing-cutting plate 26 attachedto the open feed shoe 16, thus allowing a fixed amount of the chargedfirst molding material M1 (FIG. 7C).

Next, the second molding material M2 is rubbed and cut by therubbing-cutting plate 27 attached to the second open feed shoe 17 on theturn table 1 as with the first molding material M1. Here, the temporarymolded product of the first molding material M1 held by the lower splitA and B punches 3A and 3B is pushed up into the second molding materialM2 supplied into the die 2 as the lower split A punch 3A or both thelower split A and B punches 3A and 3B are raised to predeterminedpositions using the lower split A punch track 24 and the lower split Apunch lowerer 20 or further the lower split B punch track 21 and thelower split B punch lowerer 22, thus causing the excess amount of thesecond molding material M2 to overflow. Further, the overflowing secondmolding material M2 is rubbed and cut by the rubbing-cutting plate 27attached to the second open feed shoe 17, thus allowing a fixed amountof the charged second molding material M2 (FIG. 7H).

The die and the punches charged with fixed amounts of the moldingmaterials next enter the compression molding units 9, 10 and 11. Thecompression molding units are intended to perform precompression or maincompression on either of the first and second molding materials M1 andM2 or both thereof (including the temporary molded product) usingcompression rollers 28 to 37 held by the frame 18. While precompressionmay be carried out at the same high compression pressures as for maincompression, it is normally preferred that temporary compression at lowcompression pressures be performed.

In detail, precompression of the first molding material M1 is carriedout by pressing using the upper split A punch 4A and the lower split Apunch 3A. The upper split A punch 4A is lowered by an upper split Apunch lowering cam 39 furnished on an upper split A punch track 38, andpreferably the upper split B punch 4B is also concurrently lowered to apredetermined position by an upper split B punch lowering cam 42furnished on an upper split B punch track 41, thus inserting the tip ofthe upper split A punch 4A into the space above the lower split A punch3A and enclosed by the lower split B punch 3B within the die 2. Thefirst molding material M1 charged into the given space is thus confinedfrom above and below and pressed so as to be sandwiched between theupper and lower compression rollers 28 and 29, thus molding a temporarymolded product (FIG. 7D).

Precompression (temporary compression) of the temporary molded productfrom the first molding material M1 and the second molding material M2 iscarried out by pressing using the upper split A and B punches 4A and 4B(upper punches) and the lower split A and B punches 3A and 3B (lowerpunches). To insert the upper split A and B punches 4A and 4B into thedie 2, the upper split A and B punches 4A and 4B are lowered topredetermined positions using an upper split A punch lowering cam 40furnished on the upper split A punch track 38 and an upper split B punchlowering cam 43 furnished on the upper split B punch track 41, insertingthe punch tips into the die 2. The temporary molded product from thefirst molding material M1 and the second molding material M2 areconfined so as to be sandwiched from above and below and press-molded ina preliminary fashion by upper split A and B punch precompressionrollers 30 and 32 and lower split A and B punch precompression rollers31 and 33.

In main compression following precompression (temporary compression),the molded product press-molded in a preliminary fashion is press-moldedas is in a full scale manner by upper split A and B punch maincompression rollers 34 and 36 and lower split A and B punch maincompression rollers 35 and 37 (FIG. 7I). It is to be noted that althoughnot preferred, it is possible to omit the precompression of thetemporary molded product from the first molding material M1 and thesecond molding material M2 and perform only the main compression.

Next, the residual molding material removal unit 12 is provided at theprecompression location of the first molding material M1 or a locationimmediately thereafter. As shown in FIG. 7, in the precompression stepor immediately thereafter, the lower split B punch 3B is held such thatthe extreme tip portion thereof is maintained at the same height as thesurface of the turn table 1, thus removing the first molding material M1remaining on the upper end surface of the lower split B punch 3B bycompressed air injection and suction, etc.

In detail, an upper end surface 19B of the lower split B punch 3B shownin FIG. 7 corresponds to a curving surface 84 of the finished productshown in FIG. 6, and a residual molding material R1 remains at thelocation. The residual molding material R1 is impossible to remove byrubbing and cutting using the rubbing-cutting plates 26 and 27 of theopen feed shoes or agitation feed shoes provided on the turn table 1,and there is a concern of contamination of the first and second moldingmaterials M1 and M2 if the residual molding material is in a stateunremoved. In the present embodiment, for this reason, the residualmolding material R1 is removed by the residual molding material removalunit 12 furnished on the turn table 1 following the precompression step(FIG. 7E). A residual molding material removal device constituting theresidual molding material removal unit comprises, for example as shownin FIG. 33, compressed air injection nozzles 44 for injecting compressedair onto the die surface from all directions and suction boxes 46 and 47provided with suction hole 45 for aspirating the residual moldingmaterial, with the compressed air injection nozzles 44 and the suctionboxes 46 and 47 arranged on and parallel with the surface of the turntable 1 so as to sandwich the die and the punches. The compressed airinjection nozzles 44 inject compressed air onto the punches and the diefrom all directions and further the residual molding material R1 isaspirated by the suction hole 45 near the die surface, keeping theresidual molding material R1 from flying outside for reliable removal ofthe residual molding material R1.

The final molded product is sent to the product unloading portion 13 forejection outside the molding apparatus. The product unloading portion isdesigned to unload the product using a scraper 48 that guides to a chute49 by pushing up the product as the lower split A and B punches 3A and3B rise.

In detail, the upper split A and B punches 3A and 3B are raised alongthe rising sloped surface by upper split A and B punch raising cams 50and 51, thus pulling the punch tips out of the die 2. Further, usinglower split A and B punch push-up rails 52 and 53, the lower split A andB punches 3A and 3B are pushed up, thus completely pushing a moldedproduct 54 out of the die 2. The molded product 54 that has been pushedout is scraped using the scraper 48 for unloading outside the turn table1 and then guided into the chute 49 for unloading of the product.

In the apparatus of the present invention shown in FIG. 32, means formoving the split A and B punches refer to the tracks (the lower split Bpunch track 21, the lower split A punch track 24, the upper split Bpunch track 41, the upper split A punch track 38), the lowerers (thefirst lower split A punch lowerer 19, the second lower split A punchlowerer 20, the lower split B punch lowerer 22), the raising cams (theupper split A and B punch raising cams 50 and 51), the lowering cams(the upper split A punch lowering cams 39 and 40, the upper split Bpunch lowering cams 42 and 43), the push-up rails (the lower split A andB punch push-up rails 52 and 53), the vertical sliding motion adjustmentrollers (the lower split B punch vertical sliding motion adjustmentroller 23, the upper split B punch vertical sliding motion adjustmentroller 55), the lower split A punch bottom portions 25 (same locationsas the lower split A punch compression head 25; including those for theupper and lower split punches) and the bearings 71. On the other hand,means for allowing manipulation of the split A and B punches forcompression operation refer to the compression rollers (the upper andlower precompression rollers 28 and 29, the upper split A and B punchprecompression rollers 30 and 32, the lower split A and B punchprecompression rollers 31 and 33, the upper split A and B punch maincompression rollers 34 and 36, the lower split A and B punch maincompression rollers 35 and 37), the split B punch compression head 70shown in FIG. 27 and the split A punch compression heads 25 (includingthose for the upper and lower punches). It is to be noted that theseinclude not only elements of the apparatus main body but also those ofthe punches. It is also to be noted that the number of punches capableof sliding motion or compression can be increased by increasing thecompression rollers, the tracks and so on.

As already described in relation to the punches, means for moving thesplit A and B punches or means for allowing manipulation of the split Aand B punches for compression operation include not only the method ofcontrolling the motions of the split B punches by the vertical slidingmotion adjustment rollers and tracks thereof and the motions of thesplit A punches by the split A punch bottom portions (substantially thesame location as the split A punch compression heads) and tracks thereof(corresponds to the punches shown in FIG. 27) as shown in FIG. 32 butalso an alternative method that is a reverse thereof in which themotions of the split A punches are controlled by the vertical slidingmotion adjustment rollers and tracks and the motions of the split Bpunches by the punch bottom portions and tracks (FIG. 28).

A description has been given so far of the embodiment of the apparatuscorresponding to the aforementioned second embodiment of themanufacturing method of the present invention (FIG. 7) as the apparatusof the present invention that is the rotary press for manufacturing amolded product consisting of a plurality of molded parts part of whoseat least two molded parts faces outside of the molded product. As forthe rotary presses corresponding to embodiments other than the above, itis possible to readily construct such rotary presses by selecting splitpunches suitable for respective manufacturing steps and molded productand incorporating means for moving the respective split punches andmeans for allowing manipulation of the split punches for compressionoperation in conformance with the apparatus corresponding to the secondembodiment.

A description will be given next of molded products that can bemanufactured by the rotary press for manufacturing a molded productconsisting of a plurality of molded parts part of whose at least twomolded parts faces outside of the molded product and whose charactersand/or graphics can be externally identified.

The molded product of the present invention whose characters and/orgraphics can be externally identified is characterized in that theproduct consists of a plurality of molded parts part of whose at leasttwo molded parts faces outside of the molded product, that thecharacters and/or graphics is shaped by at least one molded part andthat the molded part shaping the characters and/or graphics differs fromother molded parts in color. That is, the molded product allows theshape of the characters and/or graphics, represented by at least onemolded part, to be correctly externally identified by difference incolor between molded parts. Here, the term “molded parts” refers topress-molded parts obtained by directly compressing and molding moldingmaterials such as bulk materials as described earlier. That is, suchparts are fundamentally different from molded parts, etc. manufacturedby cast molding or plastic molding.

The molded product of the present invention is basically that which canrepresent characters and/or graphics by molded parts of different colorfrom other molded parts. In the present molded products, while part ormajority of the molded parts shaping characters and/or graphics may becovered by other molded parts and the molded parts shaping charactersand/or graphics may shape the outline of the molded product, anintermediate configuration therebetween may also be used. While onemolded part may be used to represent characters and/or graphics, aplurality of molded parts may also be used to do so. The fact that somemolded parts shape characters and/or graphics means that other moldedparts different in color also naturally shape the characters and/orgraphics or part thereof in the same outline at the adjacent locations.

The fact that two molded parts are different from each other in colorliterally means that there is a difference in color between the twomolded parts and more precisely a difference in color relatedinformation in terms of one or more options selected from among hue,brightness and chroma. Further in detail, this indicates that theabsolute value, defined by ΔL*, Δa*, Δb* that are the differences incoordinates L*, a*, b* in the L*a*b* color specification system, is 0 ormore. It is to be noted that use of one transparent molded part may bepossible in applications other than drugs. In this case, the moldedparts can be said to be different in color if the other molded part isnot transparent or if the part is different in degree of transparency.The term “characters and/or graphics” in the present invention refers tonumbers and also characters in a narrow sense as far as characters areconcerned and more specifically includes languages in a broad sense suchas numbers, kanji, hiragana, katakana and English. The term “graphics”,on the other hand, means shapes conveying some kind of meaning such asmarks, signs, emblems and trademarks and further all graphics in a broadsense such as graphics and symbols used simply from the viewpoint ofdesign. It is to be understood that characters and graphics may be usedalone or together.

It is possible according to the present invention to mass-produce moldedproducts whose characters and/or graphics of the same standard can beexternally identified. That is, the present invention makes it possibleto provide a set of molded products whose characters and/or graphics ofthe same standard can be externally identified. The term “of the samestandard” refers to the fact that the shapes, colors and absolutepositions of the molded parts, within the final molded product, thatshape characters and/or graphics remain unchanged. It is possibleaccording to the present invention to arrange specific molded partscorrectly at specific positions since the manufacturing method thereofhas the property to prevent displacement of molded parts. Further, thepresent invention uses molding materials of different colors so as toensure that the molded parts shaping characters and/or graphics differin color from other molded parts. Since respective molding materials maybe of the same origin, these molding materials basically remainunchanged in color between molded products. Assuming conventionalprinting, the shape and color may change due to “faded print”, and theposition readily moves due to “print deviation”, which makes the presentinvention stand in contrast to the prior art. It is to be noted that theterm “a set of molded products” refers to a number of mass-producedmolded products that may be, for example, 1000 pieces or more or 10000pieces or more.

A further detailed description will be given below of the case in whichthe molded product of the present invention whose characters and/orgraphics can be externally identified is used for drugs.

It suffices for the molded product of the present invention whosecharacters and/or graphics can be externally identified to be shaped soas to be easy to hold or so as not to cause malaise when consumed and isnot specifically limited. However, it is preferred that the moldedproduct be circular or elliptical as with ordinary drugs.

It suffices for the molded product of the present invention whosecharacters and/or graphics can be externally identified to be sized soas to be insertable into the mouth and so as not to involve difficultiesin deglutition, and it suffices, in the case of a circular tablet, todesign the tablet to be about 16 mm or less in diameter or 3 mm to 16 mmin diameter and preferably 5 mm to 13 mm in diameter.

Various additives regularly used in the field of formulation technologysuch as filler, binder, disintegrator, lubricant and anti-cohesion agentmay be, if desired, mixed into molding materials for respective moldedparts of the molded product of the present invention whose charactersand/or graphics can be externally identified. The amount of additionthereof may be used without any problem based on the scope of knowledgeregularly used in the field of formulation technology. It is alsopossible to obtain a pleasant feeling of consumption by flavoring orscenting respective molded parts with sweeteners and scenting agentsregularly used in the field of formulation technology.

As for coloring agents that may be used for coloring molded parts, itsuffices to use those regularly used in the field of formulationtechnology. Possible coloring agents include yellow ferric oxide, redferric oxide, amaranth, amaranth aluminum lake, tartrazine, tartrazinealuminum lake, fast green FCF, fast green FCF aluminum lake, brilliantblue, brilliant blue aluminum lake, copper chlorophyll, etc.

It is to be understood that while ingredients allowed to be contained inrespective molded parts may be used as is, granulated granular substancemay be prepared once by granulation by a normal method and sized asnecessary for use. It is also possible to prepare granulated granularsubstance by coating the main ingredient and a binder on an inactivecarrier. In the case of an active ingredient of drugs, granulatedgranular substance may be further coated as necessary with sustainedrelease capsule, time lag capsule, enteric capsule, gastric capsule,water soluble capsule, etc.

Next, a detailed description will be given of the method formanufacturing the molded product of the present invention whosecharacters and/or graphics can be externally identified.

The molded product of the present invention whose characters and/orgraphics can be externally identified can be readily manufactured usingthe rotary press of the present invention for manufacturing a moldedproduct consisting of a plurality of molded parts part of whose at leasttwo molded parts faces outside of the molded product. That is, it isbasically possible to manufacture the molded product of the presentinvention using compression molding means provided with punches aboveand below the die, the upper and lower punches having a double structureconsisting of a center punch and an outer punch enclosing part or wholeof the outer perimeter of the center punch, the tip portion of thecenter punch and/or the outer punch being shaped to represent charactersand/or graphics and both the center and outer punches being slidable andmanipulatable for compression operation, and by using molding materialsof different colors from each other for the molded part shaping thecharacters and/or graphics and the other molded part. It is alsopossible to use punches having a further complex split structure ormultistructured punches, while on the other hand, a normal punch with nosplit structure may be used for the lower punch. While theaforementioned compression molding means are preferably the rotary pressof the present invention for manufacturing a molded product consistingof a plurality of molded parts part of whose at least two molded partsfaces outside of the molded product, manufacture can be accomplished bymanipulating the die and the punches with a manual press. It is to beunderstood that compression molding by following a series of steps usingonly a set of die and punches is referred to as integral molding. Forinstance, conventional press-coated molded products have beenmanufactured by molding the center molded part in advance with one pressand supplying the part to another press halfway through the moldingstep, and the term “integral molding” has an implication that stands incontrast to such a conventional method. If the molded product of thepresent invention whose characters and/or graphics can be externallyidentified is thus defined, the features thereof manifest themselvesparticularly in the case of integral molding.

Next, a description will be given of the shape of the tip portions ofthe punches used for manufacturing the molded product of the presentinvention whose characters and/or graphics can be externally identified.

The fact that characters and/or graphics is shaped by at least onemolded part means that the punch tip portions are shaped to representthe characters and/or graphics and that, when viewed from the moldedparts, one or a plurality of molded parts formed by the punchesrepresent the characters and/or graphics. In the example describedlater, “SA” or “Y1” is shaped, and although basically based on the shapeof the tip portion of a single punch, each of these shapes consists of aplurality of molded parts as far as molded parts are concerned. Indetail, such shapes correspond to the punch tip portions illustrated inFIG. 40. In FIG. 40, FIG. 40A-1 shows the tip portion of a center punch,and FIG. 40A-2 the tip portion of an outer punch. While at least theupper punch takes on such a form, the same form is commonly employed forboth upper and lower punches. The same holds true for the tip portionsshown in FIGS. 40B to 40E. The series of punches shown in FIGS. 40A to40C are those designed to manufacture molded products in which themolded part molded by the center punch shapes characters and/orgraphics. The punches shown in FIG. 40D are used to manufacture moldedproducts in which the molded part molded by the outer punch shapescharacters and/or graphics. The punches shown in FIG. 40E are designedto manufacture molded products in which respective molded parts moldedby the center and outer punches shape characters and/or graphics. While,in the series of punches shown in FIGS. 40A, 40B and 40D, the centerpunch is completely enclosed by the outer punch, part of the centerpunch is enclosed by the outer punch in the series of punches shown inFIGS. 40C and 40E. It is to be noted that if the center punch is dividedinto “S” and “A” as in the case of the punch of FIG. 40A, it ispreferred that the tip portion of a single center punch be branched intotwo portions—one for shaping S and the other for shaping A, forexample—rather than using two independent punches as described earlier.Similarly, it is preferred that the molded part molded by the outerpunch be the center portion of the center molded part “A” shaping thealphabet (corresponds to the inside enclosed within “A”). Thus, in thecase of a molded product in which molded parts coexist in a complexmanner, it is also preferred that a plurality of molded parts other thanthat shaping characters and/or graphics be molded by a single punchbranched at the tip portion rather than by a plurality of independentpunches. Thus, branching the tip portion of a single punch ensures thatthe same amount of pressure is transferred to a plurality of moldedparts at the same speed during compression, thus maintaining the samemoldability. Moreover, no complex form will result due to the punchstructure, offering additional advantages in terms of punch manufactureand operation. Further, this allows simplification of the punch controlmeans on the main body of the molding apparatus. It is also possible tohave an integral punch structure by using a single structural body forthe punch shell portion and a separate structural body for the punch tipportion and fastening the shell portion and a plurality of punch tipportions. It is alternately possible, although not preferred, to use aplurality of independent punches rather than a single punch branched atthe tip thereof.

From here onwards, various embodiments will be illustrated in relationto the molded product whose characters and/or graphics can be externallyidentified and the manufacturing method thereof.

First, a description will be given of a cylindrical molded product inwhich the surrounding and side portions of the molded part shaping thealphabets “SA” are enclosed by the molded part of different color asshown in FIG. 38. The molded product can be manufactured by a methodthat conforms to the first embodiment (FIG. 5) using different colorsfor the first and second molding materials. Both the upper and lowerpunches used in this case have a double structure in which the tipportion of the center punch (FIG. 40A-1) shapes the alphabets “SA”, withthe tip portion of the outer punch (FIG. 40A-2) completely enclosing thetip portion of the center punch (FIG. 40A-1).

A description will be given next of a convex molded product in which themolded part shaping the alphabet and number “Y1” projects on one side ofthe molded product as shown in FIG. 39. The molded product can bemanufactured by a method that conforms to the second embodiment (FIG. 7)using different colors for the first and second molding materials. Thepunches used in this case are those similar to the aforementionedpunches in which the tip portion of the center punch shapes “Y1.”

In addition to the above, if molding materials of apparently differentcolors are used as shown in the figures for the molded productsmanufactured using the rotary press of the present invention andconsisting of a plurality of molded parts part of whose at least twomolded parts faces outside of the molded product shown in the specificexamples of steps for manufacturing a molded product, then these moldedproducts can be said to be externally identifiable. In the embodiment ofFIG. 41, it is also possible to manufacture a molded product having amolded part shaping characters and/or graphics on the surface of themolded product by using the upper center punch for shaping charactersand/or graphics, reducing the amount of the second molding material andperforming precompression only on the center punch portion in FIG. 41Hand removing surrounding molding material as residual molding material.

It is to be understood that the technical scope of the present inventionis not limited by the aforementioned embodiments.

INDUSTRIAL APPLICABILITY

The rotary press of the present invention makes possible mass productionof molded products, among other molded products consisting of aplurality of molded parts, part of whose at least two molded parts facesoutside of the molded products and is applicable to drugs, foods,sanitary products and living miscellaneous goods, metallurgy, electronicsemiconductors and so on. The present invention also provides a new codeidentification system for molded products.

1. A rotary press for manufacturing a molded product comprised of aplurality of molded parts of which at least two molded parts faceoutside of the molded product, the rotary press having a rotatable turntable that is provided with a die having a die hole, holding upper andlower punches above and below the die so as to be vertically slidable,and being designed to compress molding materials supplied and chargedinto the die by moving the upper and lower punches in mutuallyapproaching directions and pressing the molding materials with the punchtips in a state inserted in the die, the rotary press comprising: anupper punch and a lower punch each of which is split into a plurality ofsplit punches, and the tip surface of said lower punch has a concaveportion; means for moving each of the plurality of split punches andmeans for allowing manipulation of at least two of the plurality ofsplit punches for compression operation; a first molding materialsupply-charging unit for supplying and charging a first molding materialinto a space in the die formed above the tip portion of the lower punchor formed by the tip portions of the plurality of split punches of thelower punch; a second molding material supply-charging unit forsupplying and charging a second molding material into a space formedabove and around the first molding material in the die; a precompressionmolding unit for compression-molding at least one of the moldingmaterials supplied and charged; a main compression molding unit forcompression-molding the entire molded product; and a residual moldingmaterial removal unit operable to remove residual molding materials thatare left behind in the concave portion of the lower punch after theoperation of rubbing-cutting plates and before the addition of a furthermolding material.
 2. The rotary press according to claim 1, furthercomprising a precompression molding unit for compression-molding each ofthe molding materials supplied and charged.
 3. The rotary pressaccording to claim 1, wherein at least one of the lower split punches isfurther split as opposed to the corresponding upper split punch and partor whole of a residual molding material remaining on the lower punch canbe rubbed and cut by a rubbing-cutting plate as the split punch israised.
 4. The rotary press according to claim 2, wherein at least oneof the lower split punches is further split as opposed to thecorresponding upper split punch and part or whole of a residual moldingmaterial remaining on the lower punch can be rubbed and cut by arubbing-cutting plate as the split punch is raised.
 5. A molding pressfor manufacturing a molded product comprised of a plurality of moldedparts, at least two of which face outside of the molded product, whereinthe molding press comprises: an upper punch; a lower punch; wherein eachof the lower punch and the upper punch is split into a plurality ofsplit punches; wherein a tip surface of said lower punch defines aconcave space above the tip surface of the lower punch; punch driveapparatus operable to move at least one of the upper and lower punchesin a compression direction towards the other of the upper and lowerpunches; first molding material supply-charging apparatus operable tosupply a first molding material into a space above the tip surface ofthe lower punch; second molding material supply-charging apparatusoperable to supply a second molding material into a space adjacent thefirst molding material supplied into the space above the tip surface ofthe lower punch; precompression molding apparatus operable in aprecompression molding operation to compression-mold at least the firstmolding material supplied into the space above the tip surface of thelower punch; main compression molding apparatus operable in a maincompression operation to compression-mold a molded product comprisingthe precompressed first molding material and the second moldingmaterial; and residual molding material removal apparatus operable toremove residual molding material remaining in the concave space abovethe tip surface of the lower punch after the precompression operation isbegun and before a further molding material is supplied into the spaceabove the tip surface of the lower punch.
 6. The molding press of claim5, and further comprising at least one rubbing-cutting plate operable toremove molding material from the space above the tip surface of thelower punch, wherein the residual molding material removal apparatus isoperable to remove molding material remaining in the concave spacedefined by the tip surface of the lower punch after the molding materialhas been removed from the space above the tip surface of the lower punchby the operation of the rubbing-cutting plate.
 7. The molding press ofclaim 5, wherein the precompression molding apparatus is operable in theprecompression molding operation to compression-mold both of the firstand second molding materials supplied into the space above the tipsurface of the lower punch.
 8. The molding press of claim 5, wherein themolding press is a rotary press that includes a rotary turntable.